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So I increased dead band to 1 and following error to 1 and still get the same results. I used my power supply to run the drives and they work perfectly when I force a +/- voltage.

Hello PCW, tommylight,
Yes, I have switched to the optional Realtec Network Controller, because with the Intel i got triple as bad pings as with the Realtec when using it for the Mesa Card. (The Intel is very unstable indeed, Internet sometimes connects only with fixed IP, sometimes only with DHCP, that has cost me nerves the last weeks)

hanno@Linuxcnc-1:~$ lspci  | grep -i ether
00:19.0 Ethernet controller: Intel Corporation 82579LM Gigabit Network Connection (Lewisville) (rev 04)
02:00.0 Ethernet controller: Realtek Semiconductor Co., Ltd. RTL8111/8168/8411 PCI Express Gigabit Ethernet Controller (rev 15)
I try to find the DKMS driver, if you say this could help.
(oops, trying to load DKMS, I see "dkms ist schon die neueste Version (3.0.10-8+deb12u1)." But I can install/write the driver with r8168 new. I wait until I have done all the steps for that driver.

tommylight: ip a gives back:
hanno@Linuxcnc-1:~$ ip a
1: lo: <LOOPBACK,UP,LOWER_UP> mtu 65536 qdisc noqueue state UNKNOWN group default qlen 1000
    link/loopback 00:00:00:00:00:00 brd 00:00:00:00:00:00
    inet 127.0.0.1/8 scope host lo
       valid_lft forever preferred_lft forever
    inet6 ::1/128 scope host noprefixroute
       valid_lft forever preferred_lft forever
2: enp2s0: <BROADCAST,MULTICAST,UP,LOWER_UP> mtu 1500 qdisc fq_codel state UP group default qlen 1000
    link/ether 00:0a:cd:00:00:1b brd ff:ff:ff:ff:ff:ff
    inet 10.10.10.2/24 brd 10.10.10.255 scope global noprefixroute enp2s0
       valid_lft forever preferred_lft forever
3: eno1: <BROADCAST,MULTICAST,UP,LOWER_UP> mtu 1500 qdisc fq_codel state UP group default qlen 1000
    link/ether 00:23:24:55:94:28 brd ff:ff:ff:ff:ff:ff
    altname enp0s25
    inet 192.168.178.22/24 brd 192.168.178.255 scope global noprefixroute eno1
       valid_lft forever preferred_lft forever

What does that mean in relation to my pings?

Thanks for your support!
Hanno


 

What would be a good base number to enter for the dead band and following error?

Thank you Tommy,
You were right that that was the PATA setting in the bios.  I changed it to AHCI, and now that interrupt is no longer on the list anymore. 
 
Unfortunately, it doesn't appear that was the cause of my jitter.

Now the only things causing interrupts are
18 - Radeon HD 4250 internal graphics
LOC - (Local timer interrupts)
RES (Rescheduling Interrupts)

Is there anyway to see what causes the RES and LOC timer interrupts to see if the jitter is caused by one of those?

Sometimes 19 also happens, but it doesn't seem to sync up with times that the jitter has variance.

For some reason the nosmt=force setting in the kernal boot parameters doesn't seem to work anymore with the rtai kernel.  Should nosmt still work in the rtai kernel?

I have the following settings in:
ro quiet skew_tick=1 nosmt=force mitigations=auto,nosmt irqaffinity=0-1 kthread_cpus=0-1 rcu_nocb_poll rcu_nocbs=2-7 nohz=on nohz_full=2-7 isolcpus=2-7 intel_pstate=disable idle=poll cpufreq.off=1 intel_idle.max_cstate=0 amd_idle.max_cstate=0 processor.max_cstate=0 nowatchdog nosoftlockup acpi_irq_nobalance noirqbalance

I'm also using the irq affinity script from:  forum.linuxcnc.org/38-general-linuxcnc-q...ead-and-irq-affinity

Should I try a pci graphics card instead of the Radeon HD4250 integrated graphics?  Any recommendations?

That fixed it.

Now I need to add a section to match the pocket to the tool when putting away the tool.

Update:
The machines works again, without unexpected real time delay and a very good latency, but i had to take the PC of my Lathe. (the lathe machine uses the Mesa 7i76e card)
That PC has a on-board graphic card, but i first tested it with the VGA that was already there and i got the same latency issues. As soon as i used the on-board vga, the latency was perfect and no "realtime errors" at start up.

I have started latency-histogram, with 4 x glxgears and a youtube video running for about 1 hour.
I first started the histogram, then opened one glxgears and waited to check if anything spikes happen. Then i opened 3 more glxgears. No latency spike. Then the youtube video and the pc was running like that for almost one hour without any change to the base thread.
On tomorrow i will run a milling program and check if anything bad happens.

Also i will connect that "latency issue PC" to the Lathe and hope there will be no problems, but i think with the Mesa card there shouldnt be any.

Arciera is hard working to try out new non-linear solvers

I'm afraid that is a bit of an overstatement, I have no experience with this and also not really the time to poke around in dark any longer. This requires somebody who actually knows what they are doing, at least somewhat.

What is needed is a robust numerical solver and then the next step is the max error fitting described in the paper.

More pictures, inside the control boxes also.
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This is absolutely a 3 axis machine mounted on a long linear axis, see my pictures, everything in white is that 3 axis machine, everything in gray is the long axis.
There are no resolvers on my machine, it has serial absolute encoders on all axis, grayscale coding and ac motor with clutch on the tool changer, pneumatic brakes on the long axis, electronic brake on the Z axis, 6450mm usable long axis, 300x300x300mm (not sure about Z) usable area on the mill. Oh yeah, it weights in at over 5 tones.
Has AC servo drive for spindle, DC servo drives for all axis.
Besides the Mesa boards, i added over 30 or 40 small relays on all outputs, should be in the pictures somewhere on the back side of the control box, used the existing drives and motors and encoders (thanks to PCW making custom firmware for me), existing e-stop loop <== this is very important not to mess with or rewire, etc etc.
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In general, this is a very hard and very complicated job even for people with experience, so take it easy, read a lot, then read again and again, and when you think you can not figure anything = take two to three days of, go out for a coffee, chase some cats in the yard, throw some stones in the river, or whatever helps you relax, then when you start again = everything starts to fall in place and make sense and seem much, much easier.

the methodology of using a measured cutter verse probing the tool setter pad with the probe is to avoid probing a moving object which can cause a misread of the actual touch probes trigger height. because no two probes will have the same exact spring rate to trigger the chance of inconsistency or a false touch probe tool length offset is much higher then if probing a solid object. granted this variance would be very small so depending on what kind of machine results tolerance you are hoping to achieve it may be within your use case.

the XOR component would allow for using the touch probe to touch off on the tool setter, it is simply using the component to gate the two discrete probe trigger signals into linuxcnc's single probe input. there are some considerations. if the touch probe is NC and is not mounted connected to the machine full time, ie.. it is plugged in or removed depending on if it is being used or not. this causes a bit of strife as the open signal when it is removed puts the probe input in a triggered state. so if this is the scenario you are using you will need to use a dummy plug to simulate the probes closed circuit at the jack. I have seen some jacks that have the ability to close upon removal of the male plug, they are used for power/charging jacks to divert the power circuit back to the battery when the plug is removed. I think I added a diagram some time ago for this in a post but when/where escapes me.

if the tool setter and touch probe both use a normally closed circuit the single input can be run in series so long as if one is removed the circuit is closed artificially.

XOR can also be used in that scenario, just depends on how you want to configure the system. there should be a stock component specifically for probing to make it easy or a prewritten hal example somewhere in the docs as this question comes up far too often not too.. if you guys come up with a working hal example or examples, we can sticky it here for PB users or other general searches to help folks get it sorted out easily.

Rotary machines for round tube are easy, just set them as normal 3 axis machine and make separate configs for each diameter, and use normal 2.5D CAM.
Square tubing is much harder to do properly.
And, i have built machine with attached rotary, almost always concluded that separate machines are better. You can not use both parts of the machine at the same time.