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I finally found the real cause.

Today i got the amplifier fault on another joint (joint 0) and I found that it the problem happened whenever I turned on the spindle.

After several attempts to measure the ground connections the machine stopped in a position where I found the machine frame was not grounded.

The reason: The spindle connector got loose. The machine frame was grounded through the spindle cable, and that cable had become loose.

All I had to do was tighten the screw of the connector. Ground connection works reliably again and the machine runs well. Phew.

So, has there been any progress on getting this sensor to market? 

I'm trying to get a laser machine built, but, this is one of the toughest issues I'm facing.  I have a MESA 7i76EU that I have been trying to interface a BCL-AMP output to.  I have the BCL-AMP connected to a Raytools BT210S002A cutting head sitting on the bench with a chunk of steel in front of it and grounded to the case of the Raytools cutting head.  Between the BCL-AMP and the 7i76EU, I have a TI SN74HCS74DR dual Schmidt Trigger Flip Flop that I'm using to divide the BCL-AMP output frequency by 2 and "clean it up" at the same time.  However, it's just not very stable.  The velocity measured by the 7i76EU jumps around about 600-700 hz.  The velocity range only seems to be around 6500 hz from 0-10mm (3/8") sensing distance, so, my positional sensitivity sucks at around 0.1 inches.  Just for giggles, I ran the signal through 4 Flip Flops to see if the 'jumping around' would decrease.  It didn't.  Which leads me to believe the instability is introduced somewhere in my circuitry or wiring.  I even tried connecting Q and Q not outputs into the MESA card as differential signals and twisted the wires.  No help.

Anyhow, This CV2 height sensing device sounds very promising.  

Based on what im reading, it does seem ill need a larger card to handle all the limit switches and 3 encoders, one for each hand-wheel. I will prob go RJ45 as the parallel ports are less and less these days.

Thinking this guy, not cheap but one stop shop correct?
store.mesanet.com/index.php?route=produc...id=399&search=7I76EU

Hello everyone. 
I know there are plenty of other threads about this topic, and I think I read them all, still I struggle to solve the issues that I am having.

My setup is:

• Dell Wyse 5070 with Celeron J4105 4-core cpu THIN CLIENT
• realtek onboard NIC
• fresh Linuxcnc 2.9.3 install
• brandnew Mesa 7i76eu, flashed with pktUART firmware

I experience issues when I startup Linuxcnc / probebasic.
Most of the time the system errors out right after startup with "error following read...". Sometimes I am "lucky" and it works for maybe 5minutes before it errors out. 

What I did so far (after reading in this forum for 2 nights):

• I ran sudo chrt 99 ping -1.001 -q 10.10.10.10 to get some statistics. Here is the result:
  
  179555 packets transmitted, 179555 received, 0% packet loss, time 180656ms
  rtt min/avg/max/mdev = 0.052/0.065/8.974/0.036
  
• disabled all BIOS options regarding power management, hyperthreading, ... etc
• Installed R8168-dkms driver (sudo apt-get install r8168-dkms)
  While searching in this forum, I found that some people had to install linux headers first. I did not do that. 
  When I run a script to identify the used drivers (JCW posted this somewhere a while ago), i get the followig result:
  ./edriver.txt
  xargs: warning: options --max-args and --replace/-I/-i are mutually exclusive, ignoring previous --max-args value
  enp1s0 : r8169
  wlp0s12f0 : iwlwifi
  
  Is this result "expected? Or did the driver installation not work?
  Other people posted that they had to install linux-headers and purge the old driver... 
  
• then I found a script that JCW posted in another thread that pins the IRQ somewhere (I honestly dont really understand whats behind this, but still this is the output):
  cnc@linuxcnc:~/gcodes$ sudo ./pinirq.txt enp1s0
  Cores: 4
  Old CPU Mask: f
  Set device enp1s0 IRQ 122 CPU mask to 8
  
  However, it did not improve my ping / latency at all. Do I need to do anything prior to that? Isolating something?

What I have not done yet:

• editing the kernel parameters in grub customizer (quiet isolcpus= 3 pcie.aspm=0 r8168.eee_enable=0 pcie_aspm=off idle=poll).
  I dont really understand what this does, therefore I hesitated to run it. 
• .... 

Another question... almost all other threads regarding this issue link to a tutorial / troubleshooting file that was hosted by @rodw on google drive, but the link is dead. Could someone provide this file?

regards and thx.
Sebastian
 

So, I've done a lot of progress . After I changed the usb  to RS232 cable( don't buy low quality RS232 to usb cable) I've been able to connect to my driver and configure the external enable and the internal disengage of the motor brake(you need to power the io from external 24v source with Leadshine) . After all this i wired a 24v Finder relay for the motor enable commanded by the mesa,when i launch the program the mesa power  the relay and enable all the drivers. Now  I'm able to move the axis from linuxcnc, but i think I'll change the basic Axis gui with probebasic for more userfriendly interface. For the motor wiring I have to thank the Leadshine tech support, they reply very fast, and for mesa i refered to this guy video  (very helpfull, the 7i76EU version it's same wiring confirmed by Mesa tech support , for shematics and 3d support prototipe refer to this  and official 7i76E pdf ). So now i've to do some tests and project all the electrical supply for all that stuff, and i have to adapt the motors to the mecanical part with new mounting plates(i think i will design them with Fusion 360 and buy them from PCBway machining or other). That's all.

Also are the drives enabled?

Typically servo drives would have an enable input that must be connected to operate
(with default setup parameters)

Note that if LinuxCNC cannot communicate with the 7I76EU, LinuxCNC will not start.

I wired all the the motors, but i can't move with linuxcnc and the mesa board , i've done the basic configuration and followed the this post  because the configurator couldn't find the mesa but after following the instruction the mesa is recognised. My issue now is that i can't command the motors from mesa and motion control of leadshine can't find the driver(i've contacted the even  the techsupport of leadshine , and no solution finded). For the wiring i followed this  and the official pdf. The wiring should be good, i don't think i've done something wrong . A the moment i've some doubts if linuxcnc can communicate with the mesa, but if i unplug the ethernet cable in linuxcnc it's reported an error so i think they are talking. I share the photo's of my wiring. 
Has anyone experienced a similar problem? Is there a way to further test the Mesa board’s output, or any diagnostics I can run in LinuxCNC? Any advice would be greatly appreciated!

 So, just arrived the order for my retrofit .  I bought Mesa 7i76EU (i've done the configuration of Linuxcnc in a hold pc), than  Leadshine ELM1  , 3 of them 750w and one small 400w  and the drivers  EL6 for all the motors with different power supply. Im bit struggling because i can't connect the Motion Studio software to my driver for some tests idk if its the cable or other. I need to do a bit of wiring, and discover where to plug the brake of the motors , becausa i mounted all but i don't understand if i have to wire it with a another circuit with relays and a powersupply or if i can control it from the driver , didn't discovered it yet i need to check the schematics a few more times. If someone has any advices , or any experience with Leadshine motors and driver it's appreciated.
 

forum.linuxcnc.org/27-driver-boards/3559...ethernet-mesa-boards
 

Remove the .DOC file, attach the full file as a normal .txt using a simple text editor.
Do not use Office suits.
-
All office files can contain macro viruses, avoid using them unless strictly necessary.

Edit:
In the mean time fix the networking
forum.linuxcnc.org/27-driver-boards/3559...ethernet-mesa-boards

That's actually rather strange behavior and may have to do with
the 7I76E analog output being unsigned.

Can you post your hal/ini files?

I would get open loop working well first with P,I,D == 0
and FF0 = 1, then try to slowly add some P and I

(you will never get good control without FF0)

Also plotting the PID output will help with diagnosis

Hi all, 

Looking for some help with my closed loop spindle. It's a no-name "AT4" chinesium VFD driving a 3kW motor and a 2.2:1 belt drive to a BT30 spindle. Control is 0-5V from a 7i76e, encoder feedback from the motor shaft. The encoder is a 2500ppr unit I had left over so I'm only using the index pulse and have the encoder in counter mode because the A/B pulses were too fast. Encoder feedback into a 7i89.

Anyway, with P only control, I see the motor hunting a lot, a slow oscillation a few hundred rpm triangular wave, but I don't think it's as a result of too high P : there still a significant offset error so the oscillation is maintained even though the error is always a negative value (spindle slower than target). Lowering the P more increases the offset but doesn't change the amplitude or frequency of the oscillation, increasing P moves the speed closer to the setpoint but again no change in the oscillations. No screenshot but I can get one later on. Because it "hunts" even though the error is large and always one side of the setpoint makes me think it's not true hunting like a system with overly high P gain? The oscillation doesn't decay over time.. same behaviour with P anywhere from 0.8 to 10. 

I reduced P way down (to 0.5) and tried to get it working by using D to stop the oscillation and I to actually hit the setpoint, but it's still a bit shit so I think it could be much improved. I added a ramp constraint to the speed command to stop the vfd erroring out. There's an accel limit on the VFD side too so maybe that's affecting the control loop?  

It's getting to it's setpoint now but there's an over-acceleration initially, then a ramp that doesn't quite keep up, and then a weird over/undershoot/dip when the ramp ends and the I term seems to take over to slowly creep the speed to the setpoint. 

Can anyone who knows controls better than me suggest a methodology to follow to improve this?

First Question.

For a 1mm jog, I originally set my MUX40.in1 to 1.0. This was resulting in an exact 4mm jog each count. To fix this I need to set the scale below to 0.25. While I can do this and get the result I want, it bothers me that I have to use a ratio instead of direct number and will be harder to decode at latter dates. It seem arbritary that each count would be 4mm exact.

setp mux4.0.in1 1 (jogs 4 mm per count)

setp mux4.0.in1 0.25 (Jogs 1 mm per count)

net encoder-counts  <= encoder.0.counts
net encoder-counts => axis.x.jog-counts

Question is, where is the actual jog value recorded in LinuxCNC.? I cold find nothing in the .ini or .hal files that seems to indicated it would jog exactly 4mm each jog count.



Second question,

Per the below, I am currently using mux4 to determine the jog scale. But my MPG switch does is not using an encoder switch but instead has 3 simple outputs of which I placed into input 26 (1x), 27(10x), 28(100x)

I got everything to work but can not find any details in .hal how to use something other than mux4 logic to place the correct scale into the axis jog. This seems like it should be simple. More or less just want if one of those pins are true, the correct scale is selected. Below is partial code referancing the scale portion. Note. Only using pins 26 and 27 at the moment due to the mux4 requirements. Other than this, everything is working fine.

# This sets the scale that will be used based on the input to the mux4
setp mux4.0.in0 0.025
setp mux4.0.in1 0.25
setp mux4.0.in2 2.5

# The inputs to the mux4 component
net scale1 mux4.0.sel0 <= hm2_7i76e.0.7i76.0.0.input-26
net scale2 mux4.0.sel1 <= hm2_7i76e.0.7i76.0.0.input-27

# The output from the mux4 is sent to each axis jog scale
net mpg-scale <= mux4.0.out
net mpg-scale => axis.x.jog-scale

---

Basically want:

if Pin 26 true then axis.x.jog-scale == 0.025
if pin 27 true then axis.x.jog-scale == 0.25
if pin 28 true then axis.x.jog-scale == 2.5

Hallo Michael,

Danke für deine Antwort.Ich habe damals(ca.8 Jahren) mit LinuxCNC schon angefangen.Da hatte ich ein TB6560 Board von Modellbau Letmathe.Ich begann mit einen (China)Kreuztisch.Dann baute ich mir eine Portalfräse.Irgendwie bin ich auf den Planetcnc Controller gestossen.Denn habe ich genommen.
Zum Schluß wollte ich wieder umsteigen auf LinuxCNC.Habe mir dann eine MESA 7i76E gekauf und einen VFD mit Spindel.
Dann wurde ich krank und das Geld wurde knapp.Da verkaufte ich die Karte und Spindel wieder.

Jetzt habe ich nur das USB Board,die Motortreiber(Endstufen) und meinen Schaltschrank denn ich damals gebaut habe.
Ich habe sogar einen Pendant gebaut.Als USB HID Device,mit einen Teensy 3.2 und Joystick/Keypad.

Jetzt wollte ich das WHB04-4 Handrad in Planetcnc integrieren.Geht aber irgenwie nicht.Habe die .rules geändert usw. ......

Ich habe mir gedacht,man könnte die 26pin Schnittstelle verwenden.Ohne viel umzuverdrahten.

Hab gleich einen Termin.Melde mich wieder.

Grüße-Martin

---

Hello Michael,

Thanks for your answer.I started with LinuxCNC back then (about 8 years ago).I had a TB6560 board from Modellbau Letmathe.I started with a (China) cross table.then I built myself a portal milling machine.somehow I came across the Planetcnc controller.because I took it.
Finally I wanted to switch back to LinuxCNC and bought a MESA 7i76E and a VFD with spindle.
Then I got sick and ran out of money, so I sold the board and spindle again.

Now I only have the USB board, the motor drivers (power amplifiers) and my control cabinet that I built back then.
I even built a counterpart as a USB HID device with a Teensy 3.2 and joystick/keypad.

Now I wanted to integrate the WHB04-4 handwheel into Planetcnc, but somehow I couldn't. I changed the .rules etc. ......

I thought you could use the 26pin interface without having to rewire much.

I have an appointment in a few minutes.

Greetings-Martin

For configurations with specific daughtercards, the daughtercard 
name is included in the file name and you can use the .pin file
to determine the content and pinout of the firmware, for example
the 7i76eu_7i76x1_pktv2d.pin file shows that the configuration
includes a V2 PktUART ( the TX and RX halves )