Machine moves when you stop program in the middle

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17 Oct 2024 18:02 #312419 by btvpimill
Not sure what infor to provide. My machine has suddenly decided to move a seems like random amount if I hit stop during a run. It did not use to do this. and sometimes it just stops where it is. But now I can't trust it. So for instance lets say it has moved to the first cut location and is spooling up the spindle. If I hit the stop button or esc button, it will slowly move in x/y/z. During the move the disp[lay will not update. Buit when it stops the DRO will update to correct position.

It does not loose its place, if I hit run it will go right back to the correct start position.
It will also do this if the spindle is up to speed and cutting. If I hit stop it will move.

If it was only X and Y, I could hobble through the job, but it may take a dive with Z which could plunge through my part.

The only changes I have made are I tried to install easy probe a few weeks ago. But seems like I have not had this issue until today.

BTW, running Axis.

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17 Oct 2024 19:05 #312423 by PCW
What hardware are you using?

A system with a failing encoder might behave in this way.

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18 Oct 2024 08:20 #312478 by btvpimill
I have servos on both Y axis (gantry style machine with dual Y screws and servos) and X axis. Stepper on Z.
5i25 card driving things. Feels like software since it doesn't loose position. It does pop an error after the move.
<can't do that(EMC_TRAJ_SET_TELOP_ENABLE) in auto mode with interpreter idle>
Not sure if that lends any help. Also I am going to try a different program, I just realized it is also a new program so maybe there is some code that does not belong.

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18 Oct 2024 14:53 #312521 by PCW
Do the commanded positions change after a stop?
 If not, this is likely a servo/hardware/encoder issue.

(at least on axis you can select commanded or actual position for the DRO)

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18 Oct 2024 17:41 #312536 by btvpimill
I have narrowed this down to something about the program I am running. I have tested about 30 times with other various older programs that all work perfect. Then I test this one and it does this. Go back to an older one and perfect again.

We even re-posted the program to see if it is something that happened yesterday, same thing today. Posted some other program and all good.

Now we are trying only half the features to see if we can isolate where the problem lies.It makes no sense to me that it could be the program, but it is hard to dispute testing over and over with same results.

Does anybody know what that error message means?

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18 Oct 2024 17:43 #312537 by btvpimill
Do the commanded positions change after a stop?

I am not sure what you mean here?

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18 Oct 2024 18:37 #312538 by btvpimill
I am satisfied that it has something to do with this program. I have no idea what it could be. 100% it will exhibit the described behavior every time. But when I change to any other program it is fine. I even tried making a program over 256K just to see if it is some size issue.That ran fine.
I can say that it seems to depend on where I stop it as to how it moves. So if I hit stop just as it is lowering Z before it starts the spindle, it mostly goes Y+ and Z-. Close to the same amount every time. (approx 3 inches in X and 2 in Z)
If I stop it when it is ramping up the spindle, it moves mostly X+ and Y+ about 4 inches each. Z moves a very small amount in Z-.
For now I am making it into 2 programs that both run fine. Again makes no sense to me but the job needs to be done.

Have fun and good luck. If anyone does find something PLEASE let me and the rest of the community know.
LinuxCNC ver 2.7.14
Debian
Attachments:

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18 Oct 2024 18:40 #312539 by btvpimill
Not sure the file attached, trying agaain
Attachments:

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21 Oct 2024 19:44 #312783 by btvpimill
Ok, I have no idea what is going on here. The program attached above just bores a series of holes. I removed holes from the CAM and tested until it didn't drift after pressing stop. When it did I thought I found the issue, but then adding back another hole brought the issue back again. So then I thought it was a program size issue. So I made a program much bigger and it worked just fine. So then I split my original program into 2 and tested each. Both seemed fine.
Until just now. I had a part that was a little too deep, so I pressed stop and guess what? It plowed through my part before stopping. So that was a $2000 part before we machine it. Turned to trash because something is not right.

Does anybody have any thoughts?
I will point out again, this is both servos and stepper, so can't be an encoder issue. It does not loose its position - it knows where it is when it stops.
It mostly makes the same move every time if I stop in the same place in the program. But stopping in a different place will have a different move.

I am at my wits end here. I can't imagine this is a bug, but it really feels like it.Could it be a RAM issue somehow?

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21 Oct 2024 21:06 #312796 by tommylight
Replied by tommylight on topic Machine moves when you stop program in the middle

I had a part that was a little too deep, so I pressed stop and guess what? It plowed through my part before stopping. So that was a $2000 part before we machine it. Turned to trash because something is not right.

To late, but, never ever do production work on a machine that is not tried and tested to function properly.
Can you please attach the hal and ini file you are using here?
In the meantime, check the ini file for "pause_position or tollchange_position" or something similar that would cause such an issue.
Also, does the machine move to the same spot when stopping the execution?
Take some screenshots of the position in DRO before stopping the program and after stopping it and upload those here on the forum.
A video of that happening might also help, use youtube and link here, if you can, or google drive.

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