Error finishing read! Iter and joint following error in Stepper machine

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03 Jul 2024 21:55 #304342 by sin-do-re
Hello guys
i am getting some errors related to stopping the movement of the axis suddenly with a Error Finishing read and joint following error although I have a 2000000 servo period.

is there anyway can I improve my ini file to get over this?
would it be ok to increase servo period further?

thank you
.# Generated by PNCconf at Sat Dec 23 11:16:08 2023
# Using LinuxCNC version:  Master (2.9)
# If you make changes to this file, they will be
# overwritten when you run PNCconf again

[EMC]
MACHINE = cbv
DEBUG = 0
VERSION = 1.1

[DISPLAY]
DISPLAY = qtvcp qtplasmac
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
MAX_FEED_OVERRIDE = 2.000000
INTRO_GRAPHIC = linuxcnc.gif
INTRO_TIME = 5
PROGRAM_PREFIX = /home/tru/linuxcnc/nc_files
INCREMENTS = 10mm 1mm .1mm .01mm .001mm
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 133.333333
MAX_LINEAR_VELOCITY = 166.666667
MIN_LINEAR_VELOCITY = 0.500000
DEFAULT_ANGULAR_VELOCITY = 12.000000
MAX_ANGULAR_VELOCITY = 180.000000
MIN_ANGULAR_VELOCITY = 1.666667
GEOMETRY = xyz
CYCLE_TIME = 100

[FILTER]
PROGRAM_EXTENSION = .ngc,.nc,.tap GCode File (*.ngc, *.nc, *.tap)
ngc = qtplasmac_gcode
nc  = qtplasmac_gcode
tap = qtplasmac_gcode

[TASK]
TASK = milltask
CYCLE_TIME = 0.010

[RS274NGC]
PARAMETER_FILE = linuxcnc.var
RS274NGC_STARTUP_CODE = G21 G40 G49 G80 G90 G92.1 G94 G97 M52P1
SUBROUTINE_PATH = ./:../../nc_files
USER_M_PATH = ./:../../nc_files


[EMCMOT]
EMCMOT = motmod
COMM_TIMEOUT = 1.0
SERVO_PERIOD = 2000000

[HMOT]
CARD0=hm2_7i96s.0

[HAL]
HALUI = halui
HALFILE = cbv.hal
HALFILE = qtplasmac_comp.hal
HALFILE = custom.hal
POSTGUI_HALFILE = custom_postgui.hal
SHUTDOWN = shutdown.hal

[HALUI]

[KINS]
JOINTS = 3
KINEMATICS = trivkins coordinates=XYZ

[TRAJ]
SPINDLES = 3
COORDINATES =  XYZ
LINEAR_UNITS = mm
ANGULAR_UNITS = degree
DEFAULT_LINEAR_VELOCITY = 10.00
MAX_LINEAR_VELOCITY = 100.00
POSITION_FILE = position.txt
NO_FORCE_HOMING = 1

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

#******************************************
[AXIS_X]
# MAX_VEL & MAX_ACC need to be twice the corresponding joint value
MAX_VELOCITY = 100.0
MAX_ACCELERATION = 750.0
OFFSET_AV_RATIO = 0.5
MIN_LIMIT = -0.01
MAX_LIMIT = 2000.0

[JOINT_0]
TYPE = LINEAR
HOME = 0.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 50.0
MAX_ACCELERATION = 375.0
# 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 = 62.50
STEPGEN_MAXACCEL = 468.75
P = 1250.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP   = 10000
DIRHOLD    = 10000
STEPLEN    = 5000
STEPSPACE  = 5000
STEP_SCALE = 88.0
MIN_LIMIT = -0.01
MAX_LIMIT = 2000.0
HOME_OFFSET = -5.000000
HOME_SEARCH_VEL = -33.333333
HOME_LATCH_VEL = -0.500000
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 1
#******************************************

#******************************************
[AXIS_Y]
# MAX_VEL & MAX_ACC need to be twice the corresponding joint value
MAX_VELOCITY = 200.0
MAX_ACCELERATION = 1500.0
OFFSET_AV_RATIO = 0.5
MIN_LIMIT = -0.01
MAX_LIMIT = 3000.0

[JOINT_1]
TYPE = LINEAR
HOME = 0.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 100.0
MAX_ACCELERATION = 750.0
# 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 = 125.00
STEPGEN_MAXACCEL = 937.50
P = 1250.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP   = 10000
DIRHOLD    = 10000
STEPLEN    = 5000
STEPSPACE  = 5000
STEP_SCALE = -88.0
MIN_LIMIT = -0.01
MAX_LIMIT = 3000.0
HOME_OFFSET = -5.000000
HOME_SEARCH_VEL = -33.333333
HOME_LATCH_VEL = -0.500000
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 2
#******************************************

#******************************************
[AXIS_Z]
# MAX_VEL & MAX_ACC need to be twice the corresponding joint value
MAX_VELOCITY = 200.0
MAX_ACCELERATION = 1300.0
OFFSET_AV_RATIO = 0.5
MIN_LIMIT = -0.0
MAX_LIMIT = 100.01

[JOINT_2]
TYPE = LINEAR
HOME = 100.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 100.0
MAX_ACCELERATION = 650.0
# 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 = 125.00
STEPGEN_MAXACCEL = 812.50
P = 1250.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP   = 10000
DIRHOLD    = 10000
STEPLEN    = 5000
STEPSPACE  = 5000
STEP_SCALE = 290.0
MIN_LIMIT = -0.0
MAX_LIMIT = 100.01
HOME_OFFSET = 104.000000
HOME_SEARCH_VEL = 10.000000
HOME_LATCH_VEL = 0.500000
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_IGNORE_LIMITS = YES
HOME_SEQUENCE = 0
#******************************************

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03 Jul 2024 22:09 #304343 by tommylight
Trying to fix hardware issues with software is never a good idea, so ini file settings can not help much as you already have the servo period set to 2 million, but why oh why did you set the P value for all axis/joints at 1250???
Set those at 500, they are servo period dependent and must be 1/servo period, in your case 1/2000000ns=500 or 1/0.002sec=500

What PC? did you disable power saving options in BIOS? did you disable hyperthreading, TMP, C states, etc?
Also, open a terminal and type
sensors
see what the CPU temperature is while running LinuxCNC, anything above 60 degree should be checked and mitigated by repasting the cooler or better cooling.

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04 Jul 2024 01:09 #304349 by PCW
Other things to check:

1. Do you have an Intel or Realtek Ethernet chip?
( there are chip specific things you can do to improve latency)

lshw -class network

Will list your Ethernet (and wireless) network hardware if you are not sure

2. Have you run a simple ping test like:

ping -i .2 -c 4 10.10.10.10
sudo chrt 99 ping -i .001 -q 10.10.10.10

The first command populates the ARP cache so the ARP lookup doesn't add time to the first ping
The second command should be run for a few minutes (and then stopped with a control C)
and the results posted here.
 

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05 Jul 2024 10:08 #304448 by sin-do-re
Hello.
to update:
this error happens specifically when torch is about to fire, it even fires for a millisecond before error occurs.

im using output2 on 7i96s to drive a relay. The relay closes circuit of torch on terminals on the generator.

attached is the output of those commands
Attachments:

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05 Jul 2024 15:13 - 05 Jul 2024 15:27 #304473 by PCW
The ping times are pretty bad.

If you have an intel Ethernet chip have you disabled IRQ coalescing?
This is described in the hm2_eth manual page:

man hm2_eth

gnipsel.com/linuxcnc/debian-12-eth.html

If you get the error right when the torch starts, that suggest a EMI 
or grounding issue . Do you have a flyback diode across the relay coil?
Last edit: 05 Jul 2024 15:27 by PCW.

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09 Jul 2024 11:06 #304742 by sin-do-re
i have made the changes to the static IP and now i have a much smaller latency (about 0.100, 0.150)

i can "torch pulse" how many times i want and it will never have problems with the plasma ON.
i even have done "torch pulse" piercing the material, moving left, piercing again with torch pulse, etc.
i can run the G-Code how many times i want, without any problems, with "torch OFF".
i can run the G-Code how many times i want, without any problems, with "IGNORE OK", and "TORCH ON", and the plasma source itslef OFF, so the relay fires but there's no arc.

if i have "torch ON", and the plasma source ON, when i run a g-code, it will pierce the first time, and at the second time to pierce, it will give me a joint following error and "Error finishing read! Iter (...) "

my next attempt is to replace the mesa board and the relay..
 

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09 Jul 2024 12:45 #304750 by tommylight
Not a Mesa issue.
Wiring/shielding/grounding issue.

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09 Jul 2024 13:05 #304751 by PCW
Is there a flyback diode across the relay coil?

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