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now the orientation works well but still no closed loop spindle control. at 1000rpm commanded it rotates 2600 rpm and that matches what i can see in halshow.  

Assuming the mechanics are good just because I built it myself is possibly not warranted That said, aside from the ballscrew I already ordered a replacement for (will probably take weeks to get here, though), I do believe the mechanics are in good operating shape.

From an electrical perspective, I'm getting an order together for ferrites and some PSU filters to cut down on noise- a lot of the noise seems to be coming from (or through) the power supply. Catching it at the source is better than trying to band-aid further down the line.

Those are the two things I know are suboptimal- fixing them may or may not be related to this problem, but definitely aren't going to hurt.

I'll hopefully get a chance to re-run the code tonight/cut air on the existing workpiece, and will report back when I get to that. I'm thinking I'll put masking tape over the -Y pocket surfaces. If the machine behaves, those shouldn't get touched. If cutting air looks OK, I can repeat in a fresh block of material. I also intend to remember to grab a screenshot of where LinuxCNC thinks it was cutting- forgot to do that last time.

I'll dig up a Windows PC to monitor the servo while I do the above and just jog the axis around. Thanks @Teknic_Servo for reminding me that's an option.

Gcode attached. I cut a couple operations from the end that I never ran, so what you see is everything that was run on this pocket. I've looked at it 5 ways (verifying coordinates in the code, viewed in LinuxCNC, FreeCAD gcode viewer, FreeCAD cut simulator, and some online viewer) and not found any issues, but would love for that to be the problem.

7i96S will do just fine.
Did you check www.eusurplus.com ?
And what is your native language? There are sections of the forum in a lot of other languages if you have difficulty with English.

stepconf doesn't know how to setup a step/dir spindle so I would
setup an unused axis for the spindle, and then edit the hal/ini files.

If you do that and post the hal/ini files, I can give you some direction
in what needs to be done.

In the last line of "remora-eth-3.0.h" from the remora component the default line is:
#define PRU_BASEFREQ 40000 // Base freq of the PRU stepgen in Hz

Try to increase that frequency and recompile/install

And a quote of Scott: "Your joint max velocity needs to he higher than the overall max velocity so that a joint can try to catch up the following error." 

Hi dbtayl,
I came across this thread and wanted to offer a suggestion that may help with further troubleshooting.
When troubleshooting things like mis-positioning, I recommend verifying the position in each of the following places:               
               - In the original command code (this would be your G-Code passed into the controller)
                -The controllers account of how many steps/quad cnts have been sent out (I'm not 100% certain of where you would find this in LinuxCNC)
                -The motors actual position
                -The motors commanded position (add/subtract the motor's tracking error to the measured position)
                -The actual position of the mechanics (This is where your cut comes into play)

This process will let you immediately narrow down whether the problem is hardware, electrical, G-Code, or a controller issue.

For verifying the motor's position, Teknic's ClearPath SD and MC motors come with a motor setup and configuration software called MSP. The MSP software includes many diagnostics tools that can be helpful when troubleshooting a machine’s/system’s performance. For example, MSP includes a digital oscilloscope which can be used to monitor different application variables in real time.With MSP you can observe the motor's measured position, tracking error, torque, and velocity command in real-time. 
Here is a short video on how to use MSP's scope tool:

I hope this is helpful. Good luck with your continued troubleshooting!
-Brendan F. Teknic Servo Systems Engineer

Ich komm leider auch damit nicht weiter, bei usr/bin/env kommt Verzeichnis nicht gefunden, wenn ich das env wegmache kommt permission denied. 

Ich hab zwei System, richtig arbeiten tut LinuxCNC 2.81, auf einem Raspberry Pi zum Testen hab ich auch 2.93 auf einem zweiten RPI installiert, die Fehler oben kommen vom dem 2.93 System, auf 2.81 passiert garnichts, vermutlich wegen alter Python Version.

Kann es auch ein grundsätzliches Problem an der RPI Installation sein?

Danke
Grüsse
Steffen

Grotius,

Nice work...  As always, glad to see you and the other main players still here working on things.  Awesome!!!

I borrowed an old pc with a very low latency of about 3-4us (still steady after 1300sec)
Unfortunately, I'm not getting any improvement, I'm still getting a following error above 2300mm/min (~38KHz)

There must be another limiting factor somewhere else, how can I improve my troubleshooting method ?
Did anyone achieve a step rate higher than 38KHz with a similar setup ?

As Royka suggested, I've tried to increase the servo period, without success. (Though, lowering it definitely makes things worse)
Also, how can I make sure that the default stepper timing are correct ?

Attached to this post, you'll find my config.

slowpoke wrote:

Spumco,

I don't want to make this irreversible, and I will try using the existing lead screws (backlash and all) at least for now.
 

Understood - if it wasn't obvious, I was kinda engaging in a little 'what-if' fantasy as if it were my lathe...

Nice thing about lathes, the backlash isn't quite as big a deal as on mills.  It's rare that you have to cut in both directions on one axis in the same toolpath (think circle on a mill).  Just write your programs with enough retract so that the backlash is taken care of when the next cut approach is made.

Regarding motor mounting, I think you'll want to mount the Z-motor outboard on the right, probably with a belt drive.  Keep the gearbox, and just leave it disconnected.  X-motor up front, and hang it under the cross slide with a belt up to the leadscrew.

Rotary SMP's minilathe series would be a good starting point for mount ideas - just scale it up to fit.

Okay. So. As you can see, i have the servomotor's Step signal connected to pin 4 and Pulse signal connected to pin 5 of my parallel port.

What should i configure these two pins as in the step config?

Where should i write stepgen and how?

How can i enable this motor? The enable of the two motors are on a common pin 6 as you can see in the image

she have vfd 1.5kw water spindle , have inductive limit switches 
and 3 axis ,,,rn have red usb mach3 card that skip more code then kangaroo 
which lan card will be best for it ?  
i look for 7i96s 220euro in eu .. but i dont understand all these versions so need to ask  
at first i was thinking to upgrade to uccnc and axbb-e for 230euro but i read every new version of uccnc
they screw up something ,dont know  
can someone give me some links what to buy how to set or just ignore and go uccnc way ?
thanks

I am happy to hear that you reached the goal.

Now we could integrate your experience in the installing intructions file.
We have NativeCAM working on LinuxCNC 2.9 and 2.10 beta, Rapberry Pi and Debian.

Yes, we have to thank BogdanTheGeek for the big job of porting NativeCAM from python2 to python3.

Regards
Giovanni

Spumco,

I don't want to make this irreversible, and I will try using the existing lead screws (backlash and all) at least for now. Not sure how well the backlash compensation will take care of that, I guess I will find out.

Looks like I can rule out network latency, good.
The pc was supplied with 1x4gb, I'll try to swap it out for a dual channel combo.

Well, all hope isn't lost, thank you Royka, I'll try to move forward with the recommendation you've provided !