Dyna Myte 2400 milling machine retrofit
04 May 2015 21:44 #58374
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
Here is my ini file data as it was when the alarms occured.
# Generated by PNCconf at Fri May 1 14:06:34 2015
# If you make changes to this file, they will be
# overwritten when you run PNCconf again
[EMC]
MACHINE = Dyna_2400_A
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/camlab/linuxcnc/nc_files
PYVCP = pyvcp-panel.xml
INCREMENTS = .1in .05in .01in .005in .001in .0005in .0001in
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 0.250000
MAX_LINEAR_VELOCITY = 1.000000
MIN_LINEAR_VELOCITY = 0.010000
DEFAULT_ANGULAR_VELOCITY = 0.250000
MAX_ANGULAR_VELOCITY = 1.000000
MIN_ANGULAR_VELOCITY = 0.010000
EDITOR = gedit
GEOMETRY = xyz
[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 = Dyna_2400_A.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal
[HALUI]
[TRAJ]
AXES = 3
COORDINATES = X Y Z
LINEAR_UNITS = inch
ANGULAR_UNITS = degree
CYCLE_TIME = 0.010
DEFAULT_VELOCITY = 0.33
MAX_LINEAR_VELOCITY = 3.33
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 = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 200
DIRHOLD = 200
STEPLEN = 4000
STEPSPACE = 4000
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 6.2
HOME_OFFSET = 0.0
#********************
# Axis Y
#********************
[AXIS_1]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = 101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 5.0
HOME_OFFSET = 0.0
#********************
# Axis Z
#********************
[AXIS_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 4.0
HOME_OFFSET = 0.0
#********************
# Spindle
#********************
[SPINDLE_9]
# Generated by PNCconf at Fri May 1 14:06:34 2015
# If you make changes to this file, they will be
# overwritten when you run PNCconf again
[EMC]
MACHINE = Dyna_2400_A
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/camlab/linuxcnc/nc_files
PYVCP = pyvcp-panel.xml
INCREMENTS = .1in .05in .01in .005in .001in .0005in .0001in
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 0.250000
MAX_LINEAR_VELOCITY = 1.000000
MIN_LINEAR_VELOCITY = 0.010000
DEFAULT_ANGULAR_VELOCITY = 0.250000
MAX_ANGULAR_VELOCITY = 1.000000
MIN_ANGULAR_VELOCITY = 0.010000
EDITOR = gedit
GEOMETRY = xyz
[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 = Dyna_2400_A.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal
[HALUI]
[TRAJ]
AXES = 3
COORDINATES = X Y Z
LINEAR_UNITS = inch
ANGULAR_UNITS = degree
CYCLE_TIME = 0.010
DEFAULT_VELOCITY = 0.33
MAX_LINEAR_VELOCITY = 3.33
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 = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 200
DIRHOLD = 200
STEPLEN = 4000
STEPSPACE = 4000
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 6.2
HOME_OFFSET = 0.0
#********************
# Axis Y
#********************
[AXIS_1]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = 101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 5.0
HOME_OFFSET = 0.0
#********************
# Axis Z
#********************
[AXIS_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 4.0
HOME_OFFSET = 0.0
#********************
# Spindle
#********************
[SPINDLE_9]
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04 May 2015 22:03 #58376
by andypugh
This seems inconsistent, your X timings are longer than the Y timings.
8000nS total cycle time and 101596 steps per inch means that it takes 0.8 seconds for your machine to move 1", which is 1.25 in/sec or 75 in/min
You have set the speeds to 3.33 in/sec and this is a speed that is simply not possible with that step timing.
The Y and Z axes have 4000nS total cycle time, they can manage 2.5 in/sec, which is better but still short of the limits being requested.
Your step scale seems very big. If X drive really does need 4000nS for step and space (is it different from the other drives?) then you might have to reduce the microstep ratio to get the speed you want.
Your machine resolution is currently 9 millions of an inch. That seems a little unnecessary.
Replied by andypugh on topic Dyna Myte 2400 milling machine retrofit
#********************
# Axis X
#********************
[AXIS_0]
...
STEPLEN = 4000
STEPSPACE = 4000
STEP_SCALE = -101596.0
...
#********************
# Axis Y
#********************
[AXIS_1]
...
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = 101596.0
This seems inconsistent, your X timings are longer than the Y timings.
8000nS total cycle time and 101596 steps per inch means that it takes 0.8 seconds for your machine to move 1", which is 1.25 in/sec or 75 in/min
You have set the speeds to 3.33 in/sec and this is a speed that is simply not possible with that step timing.
The Y and Z axes have 4000nS total cycle time, they can manage 2.5 in/sec, which is better but still short of the limits being requested.
Your step scale seems very big. If X drive really does need 4000nS for step and space (is it different from the other drives?) then you might have to reduce the microstep ratio to get the speed you want.
Your machine resolution is currently 9 millions of an inch. That seems a little unnecessary.
The following user(s) said Thank You: muzzy101
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03 Jun 2015 23:25 #59385
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
I fixed all of those issues and I have all of the axis motors and limit switches under control. Thank you for the help.
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03 Jun 2015 23:35 #59388
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
The last issue that I need to resolve is to control the on/off of the spindle. I am using a Mesa 6I25 card in the PC and a 7I76 daughter card. I need to generate a PWM signal for the spindle. The spindle speed is controlled by a manual POT, which is fine considering that the speed range is selected via belt and pully and the machine does not have an automatic tool changer. All I need to be able to do is program spindle on and off. The signal seems to be 5 volts. I have the field IO's powered with 24 volt power supply and the 6I25 is supplying 5 volts from the PC for the signals to the axis motor dirves. The spindle drive is controlled from a 5 volt power supply in the machine and is on a switch at the moment. How exactly can I generate the PWM signal through the 7I76 card?
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03 Jun 2015 23:50 #59391
by andypugh
Are you sure you want to use PWM? The 7i76 has a built-in isolated digital potentiometer. That is probably ideal for what you need.
What is the motor driver? Some have a huge voltage (120V) between the pot inut and GND. Which can be a bit surprising (DAMHIK).
See page 12 of www.mesanet.com/pdf/parallel/7i76man.pdf
Replied by andypugh on topic Dyna Myte 2400 milling machine retrofit
The spindle speed is controlled by a manual POT
...
How exactly can I generate the PWM signal through the 7I76 card?
Are you sure you want to use PWM? The 7i76 has a built-in isolated digital potentiometer. That is probably ideal for what you need.
What is the motor driver? Some have a huge voltage (120V) between the pot inut and GND. Which can be a bit surprising (DAMHIK).
See page 12 of www.mesanet.com/pdf/parallel/7i76man.pdf
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04 Jun 2015 00:14 #59395
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
The driver is the original hardware that came with the machine. We don't have any documentation on the machine so I couldn't begin to describe it. Forgive my ignorance on this subject. I'm a second year mechanical engineering student. I haven't gotten into electrical controls classes as of yet. The electrical engineering student that is working with me verified that the signal is PWM. We orginally attempted to control the spindle using the potentiometer on the 7I76 and the analog signal outputs and had no luck. The nature of the machine's design doesn't really make it necessary to control spindle speed through a program though. All I need is a programable signal to turn it on.
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04 Jun 2015 00:51 #59397
by andypugh
The electrical engineering student might need to look at his textbooks in more detail![:-) :-)](/media/kunena/emoticons/smile.png)
A manual potentiometer can not output a PWM signal. The 7i76 digital potentiometer would need to be connected in the exact same position in the circuit as the manual one.
It is entirely possible that there is a secondary input for a PWM signal. Unfortunately the 7i76 can't really do PWM much above 50Hz, as the digital IO is serviced by the servo-thread at 1kHz.
If a 50Hz PWM is OK, then you can use the software PWM generator: www.linuxcnc.org/docs/html/man/man9/pwmgen.9.html
If you need fast PWM the 5i25 can manage very fast PWM either on the secondary header on the card, or potentially by re-purposing one of the step-dir outputs on the 7i76 and using a custom firmaware on the 5i25.
Replied by andypugh on topic Dyna Myte 2400 milling machine retrofit
The electrical engineering student that is working with me verified that the signal is PWM. We orginally attempted to control the spindle using the potentiometer on the 7I76 and the analog signal outputs and had no luck..
The electrical engineering student might need to look at his textbooks in more detail
![:-) :-)](/media/kunena/emoticons/smile.png)
A manual potentiometer can not output a PWM signal. The 7i76 digital potentiometer would need to be connected in the exact same position in the circuit as the manual one.
It is entirely possible that there is a secondary input for a PWM signal. Unfortunately the 7i76 can't really do PWM much above 50Hz, as the digital IO is serviced by the servo-thread at 1kHz.
If a 50Hz PWM is OK, then you can use the software PWM generator: www.linuxcnc.org/docs/html/man/man9/pwmgen.9.html
If you need fast PWM the 5i25 can manage very fast PWM either on the secondary header on the card, or potentially by re-purposing one of the step-dir outputs on the 7i76 and using a custom firmaware on the 5i25.
The following user(s) said Thank You: muzzy101
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05 Jun 2015 00:47 #59440
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
So I think instead of using the existing spindle drive, I am going to replace it with a new spindle drive. We can get a drive from automation direct that I am fairly sure will operate on the analog spindle signal and pot output from the 7I76 card. I just need to verify that It is compatible with the existing spindle motor. Below is a link to the drive. Can you look it over and tell me if it will indeed work with the analog outputs On the 7I76? Thanks.
www.automationdirect.com/adc/Shopping/Ca...en_Frame/GSD4-240-1C
www.automationdirect.com/adc/Shopping/Ca...en_Frame/GSD4-240-1C
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05 Jun 2015 00:51 #59441
by andypugh
I don't understand why, you have a spindle drive that works, why not use it?
The drive you linked to takes 0-10V or potentiometer, so will work with the 7i76.
Replied by andypugh on topic Dyna Myte 2400 milling machine retrofit
So I think instead of using the existing spindle drive
I don't understand why, you have a spindle drive that works, why not use it?
The drive you linked to takes 0-10V or potentiometer, so will work with the 7i76.
The following user(s) said Thank You: muzzy101
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05 Jun 2015 01:05 #59443
by muzzy101
Replied by muzzy101 on topic Dyna Myte 2400 milling machine retrofit
Well, the original control worked as well, but it was old and no longer supported by the manufacturer. The intention of the project was to update the equipment with readily available parts and an operating system like linuxcnc that would enable us to easily integrate all of our machines and robots into a modular manufacturing cell. My professor originally suggested replacing that drive since we had no information at all on it. In hindsight I probably put myself in a corner by ordering the 7I76 card before I had learned enough about what we needed. But it is all a learning experience. Thank you for all of the help. I'll see how this next step goes.
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