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Well i'm trying to fix this but seem to be missing something simple.

running the linuxcnc 2.9.2 downloadable iso for debian 12

pulled master from git
Made the changes,
compiled the code with some prints  using
cd src
./configure
make
sudo make setuid 

with this code 

        case HOME_ABORT:
        rtapi_print_msg(RTAPI_MSG_ERR, "Entering HOME_ABORT state\n");
        for (int i = 0; i < all_joints; i++) {
             rtapi_print_msg(RTAPI_MSG_ERR, "Aborting joint %d\n", i);
            H[joint_num].homing = 0;
            H[joint_num].homed = 0;
            H[joint_num].joint_in_sequence = 0;
            joint->free_tp.enable = 0;
            H[joint_num].home_state = HOME_IDLE;
            H[joint_num].index_enable = 0;
         }
            immediate_state = 1;
            break;


ran it. 
prints did not show up.

Seems like I'm either
1. running the old version of linuxcnc that was installed by default. dont think so as compiling changes it? still seeing 2.9.2 which makes me question (should it be 2.10?)
2. not ever getting to that code somehow...dont think this is it as it in the only place in the source code i can find that error. 
3. getting to that code but the prints are not going through cause I'm misunderstanding how they work. 

Any help would be great!

Thanks
 

Might have found it, started an issue.

github.com/LinuxCNC/linuxcnc/issues/2983

this is in the homing.c file

here is the code throwing the error, think it calls home abort for the joint

/* check for reached end of move */
if (! (&joints[jno])->free_tp.active) {
/* reached end of move without hitting switch */
(&joints[jno])->free_tp.enable = 0;
rtapi_print_msg(RTAPI_MSG_ERR,_("j%d end of move in home state %d"),jno, H[jno].home_state);
H[jno].home_state = HOME_ABORT;
return 1; // abort reqd
}


However the home abort case only does the current joint not all of them.

case HOME_ABORT:
H[joint_num].homing = 0;
H[joint_num].homed = 0;
H[joint_num].joint_in_sequence = 0;
joint->free_tp.enable = 0;
H[joint_num].home_state = HOME_IDLE;
H[joint_num].index_enable = 0;
immediate_state = 1;
break;




simple loop might fix the issue??? hope im understanding this correctly. e.g.

case HOME_ABORT:
for (int i = 0; i < all_joints; i++) {
H.homing = 0;
H.homed = 0;
H.joint_in_sequence = 0;
H.home_state = HOME_IDLE;
H.index_enable = 0;
joints.free_tp.enable = 0;
}
immediate_state = 1;
break;

jimmyrig wrote:

z axis, if failed to home (broken stepper wire) would still cause the x and y axis to move even after it failed!!!!!! had this happen twice over the last year with the thin nema 17 wires breaking at the connectors after all those pierces.

This looks like a LinuxCNC bug, I see the same behaviour in AXIS. I get the below error message but X and Y do go through their homing sequence.

Agreed, I know of a few machines where this would cause significant damage. If nothing else it should be a default with the ability to disable.

I've got a few linuxcnc machines I don't mind helping test. I can code ok but cant find files for the life of me in Linux (C# windows guy). If someone can point me in the right area I'll do some digging.

phillc54 wrote:

jimmyrig wrote:

z axis, if failed to home (broken stepper wire) would still cause the x and y axis to move even after it failed!!!!!! had this happen twice over the last year with the thin nema 17 wires breaking at the connectors after all those pierces.

Do you mean that X and Y continue moving to home after the failure? 

This was mentioned before when PlasmaC was being developed, can not recall if this is normal behavior for LinuxCNC, but it should not be, if any joint/axis fails to trigger the switch in the given distance, it should stop homing and motion and issue a warning.
As luck would have it, two days ago i witnessed the same thing with X axis failing to reach the home switch and machine chugging along as nothing happened.
Needs more testing, probably.

Will post those files this evening.

Yep x and y would keep moving even after the z failure.

I'll try cycle stop in Debian 12 I think I tried it in the 2.10 pre version I was running and no luck. I saved that hdd so if you need any info from it will pull it back in.

Awesome on the change consumables, will give that a shot.

It's a stupid question again but I can't find the page during the configuration with pncconf where I should enter the THCAD-2 informations.
On the QtPlasmaC documentation page it says : "The THCAD screen will only appear if a Plasma Encoder is selected in the card screen". I can't seem to find how or where to do that.

jimmyrig wrote:

sometimes when using ohmic touchoff it would hit a pile of junk, bird poop, etc , and ohmic would not sense. This would cause the float switch to trip but it wouldn't continue...... would just get stuck. pause, unpause, stop, restart from line, etc nothing would make it pierce. Would required a full reset of linuxcnc, disabling ohmic, allowing it to pierce, with float, then going back to ohmic mid program. This happened ~25 times. every now and then it would work with the float if ohmic failed but not usually (or maybe i just didn't notice until it failed)

Could you post the zip file created by the BACKUP CONFIG button in the SETTINGS tab. 

z axis, if failed to home (broken stepper wire) would still cause the x and y axis to move even after it failed!!!!!! had this happen twice over the last year with the thin nema 17 wires breaking at the connectors after all those pierces.

Do you mean that X and Y continue moving to home after the failure? 

i have a custom user button to move the table to origon. However their is no way to stop the machine from software after that command has been sent (left parts on the carriage a few times whoops) requiring the estop to be hit, when a simple pause or cancel would have worked great.

Cycle Stop should stop motion, the Esc key should also stop motion if you have keyboard shortcuts enabled. 

Missing Features (hope this is around now)
the biggest one is when the program is paused (cause the tip is burnet out), not being able to move to a specific location to make changing tips easy.

Change Consumables was provided for this.

I am upgrading the table to include a 4th axis rotary and figured i would update the system to debian 12 while at it and provide a update on how things went. 

I forgot to push that update, if it wasnt made will push it when i go to debian 12. 

Well its been a while but here are the results of ~ 1 year of use. (see pic)
a little over 8.4 miles of cutting or 13.4 km, and about ~53k pierces. 
torch was on for 63 hours. 

ohmic has worked flawlessly in all kinda of weather (rain/snow)/ well below freezing to very hot. (table under a carport so kinda exposed to the weather),. I much prefer ohmic as i full rapid for each pierce so times are ~1 sec instead of the ~3-4 that probing takes.....when doing ~53k peirces that saved a day worth of run time!

a few bugs i ran into, not sure if they have been fixed as i am on the same version (been to big of a chicken to update... trying to keep up with orders so didn't want to break things) 
1. sometimes when using ohmic touchoff it would hit a pile of junk, bird poop, etc , and ohmic would not sense. This would cause the float switch to trip but it wouldn't continue...... would just get stuck. pause, unpause, stop, restart from line, etc nothing would make it pierce. Would required a full reset of linuxcnc, disabling ohmic, allowing it to pierce, with float, then going back to ohmic mid program. This happened ~25 times. every now and then it would work with the float if ohmic failed but not usually (or maybe i just didn't notice until it failed) 
2. z axis, if failed to home (broken stepper wire) would still cause the x and y axis to move even after it failed!!!!!! had this happen twice over the last year with the thin nema 17 wires breaking at the connectors after all those pierces. 
3. i have a custom user button to move the table to origon. However their is no way to stop the machine from software after that command has been sent (left parts on the carriage a few times whoops) requiring the estop to be hit, when a simple pause or cancel would have worked great. 


Missing Features (hope this is around now)
the biggest one is when the program is paused (cause the tip is burnet out), not being able to move to a specific location to make changing tips easy. 


Below is my current ohmic setup via a terrible paint drawing if anyone wants to replicate my setup.

5x5k 1w resistors for ~25kohm (22.5k in reality)  between v+ of power supply and in- of thcad.. The table connects to -in at the thcad as well
1x250kohm resistor between thcad v+ of power supply and in+ of thcad
power supply v- to torch (ohmic shield) 

With this setup when the torch is full of junk it reads ~24v letting you know the torch is messed up while allowing ohmic probing to continue
 

There is nothing in LinuxCNC that recognizes the THCAD output as Z axis feedback
This must be done entirely in the hal configuration for your machine.

What is the required resolution of the feedback signal?

That is what is the Z axis motion range and the expected accuracy?

If high resolution is required, this may suggest a 7I87 instead of a THCAD

Before purchasing the THCAD2, please, I need your professional help the procedure shown in the attached illustration (image) shows the connection diagram of the Mesa boards and the machine is allowed. The punch press has analogue drive for the Z -10 and +10 axes. I have already bought the 7i77 board and I am waiting for it to arrive, but I am worried about monitoring the Z axis as an encoder that has a magnetic sensor from 0 to 10 V, I intend to buy another THCAD2 board to convert the analog voltage from 0 to 10 V at the frequency so that does the 7i77 or 7i96s recognize it in LinuxCNC as the Z axis encoder position, can this setting be done as Z axis feedback to increase accuracy and correct positioning?

Yes, THCAD output to Mesa 7i96S encoder input.
But
No Fref, those are not used.
Only Fout to encoder A.
That also requires flashing the plasma firmware to 7i96S, it is included in the downloads on mesanet.com website.

Thanks for the info. To connect the THCAD2 board to the 7i96s board, will it be via the encoder input?

TB2 PIN 7 ENCA+ ==== PIN 2 FREF+
TB2 PIN 8 ENCA- ==== PIN 3 FREF-
TB2 PIN 9 GND ==== PIN 1 GND
TB2 PIN 10 ENCB+ ==== PIN 4 FOUT+
TB2 PIN 11 ENCB- ==== PIN 5 FOUT-
TB2 PIN 12 +5VP ==== PIN 6 +5V

Yes, a THCAD2 would likely work, forgot about that

THCAD ? 0-10V input, encoder output...
And to late but could have gotten a 7i83 for analog outputs, cheaper and easy to find, since you already have 7i96S