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I have doing some experiments today and it is possible to run ethercat sync below 1ms interuption.. I have tried 250us sync and it was fine... but I do not know how it will be outside of bench top ...my prehistoric servo drivers has limit at 250us ... I did not test them with sync motion just communication setup and I have generic ec driver only... 

It should be great to test them then anyway.. 

@Hi arciera,

That's not difficult to do, opencascade is good in vectors, planes, etc.

But then still if a or b rotates below the workpiece in one gcode line, we are lost.
The 3d clothoid works, but output is not alway's valid. So i have to review my approach.
 
Sheisse.

Well, I spent most of yesterday at this and I don't appear any further ahead. When I ran Axis on a very similar machine a number of years ago I never saw or heard about HAL. I guess I will keep at it maybe I will get a flicker of light.
Thanks for the help, Ian aka Irritant

What does it actually say? One of the messages includes "this is not ncessarily an error"

If it works in stepconf then it ought to work in LinuxCNC. The most common cause for not doing is that the linuxcnc config drives the stepper driver enable pins and stepconf never does. And many stepper drivers have high-to-disable inputs. If you defined drive enable pins, suspect this.

Have you checked if 'axis.L.jog-enable' is true and what 'axis.L.jog-scale' is set to?

If the spindle is controlled with velocity commands then it may be just a case of switching to a position PID (which still outputs velocity commands)

wiki.linuxcnc.org/cgi-bin/wiki.pl?SpindleOrient

I've gt almost everything working on my mill, but the MPG Jogging...  encoder is ounting but axis is not moving.  I'm sure its simple.  Attached are my hal and ini files.  Thank you.

No, I did not try. What does it mean? Increase encoder-offset value by 1/4 of counts/rev (switch to another electrical zero point)?
Or is it meant to be bldc.0,drive-offset pin? Should I try 90 degrees (plus or minus) or experiment with values?

I am not sure about the encoder-offset value. The way I got that value 98 is this:
I followed Andy's suggestion:
1) started LinuxCNC, setp index-enable 1, turn motor by hand until encoder counts reset to 0
2) setp 8i20.current 0.8 (motor gets strong resistance but with some effort can still be rotated by hand) and motor snaps to its desired position
3) turned motor away numerous times in both directions, let it snap back and check the encoder counts value. it was changing in range from -72 to -80 so I took the middle of -76, checked remaining 3 positions where motor wants to snap and the difference in encoder counts was very close to 1000 (full turn is 4000)
4) repeated the same with setp 8i20.current -0.8, but was not sure what to do with those values. just noticed that the difference between these snap points vs previous is not very close to 500 counts
5) tried to spin the motor with encoder-offset of -76, did not work, but +76 was good. except that there was a difference in velocities between positive and negative BLDC input value

So I started increasing the encoder-offset value and the motor velocity for the same BLDC input value started increasing until velocity did not noticably change when encoder-offset increased from 96 to 98, so I sticked to it. (I did not try decreasing initial value of 76).

So that is 20 encoder counts away from initial position to which the motor wants to snap in, but given that one electrical revolution is 1000 counts, that does not seem too much, but I have no idea about the electrical processes in servo motors.

Please let me know what else could I check and try.

Maybe because linear and angular moves have different velocity units.

A 7I96S has this built in (TB2 pins 22..24)
This is supported by all 7I96S firmware

It really seem like an initial orientation angle problem
have you tried using a bldc offset of 90 degrees?

The reason for stepgens with no direction pins is that the firmware is built
for a drive or breakout (say a G540 or CNC4PC C11) that has a chargepump or
watchdog and a stepgen is used to generate the signal the drives that pin.

There are standard parallel port type pinouts for the 7I92T that have 5 complete
stepgens, like  7i92t_5abobx2d.bin

I see the problem.
I wonder if it were easier to project the two segments (ie the two thick blue arcs) onto the plane defined by the tool orientation vector that passes through the intersection point. How difficult would it be for your algo to calculate the plane defined by a vector and it's corresponding TA/TO knot and then do the projection? Is that possible at all?

Gentlemen,
 Why does task/emccannon.cc care about 'Pure linear move' or 'Pure angular move' or 'Combination angular and linear move'?

Is that because when that code was written the processors and memory were much slower and smaller?

thanks
Stuart
 

Thank you cornholio for your answer. I don't want to bother Pete for now for a customized configuration. I am just looking for a solution to have 5 stepgens on the same connector P2 of the 7i92t to control X, dual Y, Z, A on a milling machine.