Automatic spindle gear detection

#/* # * gears.hal # * This file is part of gears.comp # * # * Copyright (C) 2014 - Marius D iLebenberg # * # * gears.comp is free software; you can redistribute it and/or modify # * it under the terms of the GNU General Public License as published by # * the Free Software Foundation; either version 2 of the License, or # * (at your option) any later version. # * # * gears.comp is distributed in the hope that it will be useful, # * but WITHOUT ANY WARRANTY; without even the implied warranty of # * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the # * GNU General Public License for more details. # * # * You should have received a copy of the GNU General Public License # * along with gears.comp; if not, write to the Free Software # * Foundation, Inc., 51 Franklin St, Fifth Floor, # * Boston, MA 02110-1301 USA # * # * THE AUTHORS OF THIS LIBRARY ACCEPT ABSOLUTELY NO LIABILITY FOR # * ANY HARM OR LOSS RESULTING FROM ITS USE. IT IS _EXTREMELY_ UNWISE # * TO RELY ON SOFTWARE ALONE FOR SAFETY. Any machinery capable of # * harming persons must have provisions for completely removing power # * from all motors, etc, before persons enter any danger area. All # * machinery must be designed to comply with local and national safety # * codes, and the authors of this software can not, and do not, take # * any responsibility for such compliance. # * # * This code was written as part of the LinucCNC HAL project. For more # * information, go to www.linuxcnc.org. # */ loadrt gears addf gears.0 servo-thread loadrt lowpass names=lowpass.spindle loadrt scale names=scale.spindle loadrt timedelay addf scale.spindle servo-thread addf lowpass.spindle servo-thread addf timedelay.0 servo-thread ############### SPINDLE SIGNALS ############# net spindle-on-in gears.0.spindle-en-in #net spindle-on-out gears.0.spindle-en-out => hm2_5i25.0.7i76.0.0.spinena net spindle-gain gears.0.spindle-gain-out => scale.spindle.gain net spindle-speed motion.spindle-speed-out-abs => gears.0.spindle-cmd-in net spindle-speed-out gears.0.spindle-cmd-out => scale.spindle.in #net spindle-speed-dac scale.spindle.out => hm2_5i25.0.7i76.0.0.spinout net spindle-at-speed gears.0.spindle-at-speed-out ############## FEEDBACK SIGNALS ############# setp lowpass.spindle.gain 0.007 #net spindle-vel-fb-in hm2_5i25.0.encoder.00.velocity => lowpass.spindle.in net spindle-vel-fb-co lowpass.spindle.out => gears.0.spindle-fb-in ############## TIMEDELAY #################### net delay-value timedelay.0.on-delay <= gears.0.time-delay net delay-trigger-in timedelay.0.in <= gears.0.timer-on net delat-trigger-out timedelay.0.out => gears.0.timer-off ############## VCP/GLADE PANEL ############## net button-on gears_panel.hal-btn-go => gears.0.go-btn net current-gear gears_panel.hal-lbl-gear-curr => gears.0.gear-curr net requested-gear gears_panel.hal-lbl-gear-req => gears.0.gear-req ############## PARAMETERS ################### setp gears.0.spindle-max 2250 setp gears.0.spindle-max-gain 0.004 setp gears.0.gear-max-00 170 setp gears.0.gear-min-00 40 setp gears.0.gear-delay-00 1 setp gears.0.spindle-gain-00 0.058 setp gears.0.gear-max-01 270 setp gears.0.gear-min-01 170 setp gears.0.gear-delay-01 2 setp gears.0.spindle-gain-00 0.037 setp gears.0.gear-max-02 540 setp gears.0.gear-min-02 270 setp gears.0.gear-delay-02 3 setp gears.0.spindle-gain-00 0.0185 setp gears.0.gear-max-03 830 setp gears.0.gear-min-03 540 setp gears.0.gear-delay-03 4 setp gears.0.spindle-gain-00 0.012 setp gears.0.gear-max-04 1320 setp gears.0.gear-min-04 830 setp gears.0.gear-delay-04 5 setp gears.0.spindle-gain-00 0.0075 setp gears.0.gear-max-05 2620 setp gears.0.gear-min-05 1320 setp gears.0.gear-delay-05 6 setp gears.0.spindle-gain-00 0.00381

/* * gears.comp * This file is part of gears.comp * * Copyright (C) 2014 - Marius D Liebenberg * * gears.comp is free software; you can redistribute it and/or modify * it under the terms of the GNU General Public License as published by * the Free Software Foundation; either version 2 of the License, or * (at your option) any later version. * * gears.comp is distributed in the hope that it will be useful, * but WITHOUT ANY WARRANTY; without even the implied warranty of * MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the * GNU General Public License for more details. * * You should have received a copy of the GNU General Public License * along with gears.comp; if not, write to the Free Software * Foundation, Inc., 51 Franklin St, Fifth Floor, * Boston, MA 02110-1301 USA * * THE AUTHORS OF THIS LIBRARY ACCEPT ABSOLUTELY NO LIABILITY FOR * ANY HARM OR LOSS RESULTING FROM ITS USE. IT IS _EXTREMELY_ UNWISE * TO RELY ON SOFTWARE ALONE FOR SAFETY. Any machinery capable of * harming persons must have provisions for completely removing power * from all motors, etc, before persons enter any danger area. All * machinery must be designed to comply with local and national safety * codes, and the authors of this software can not, and do not, take * any responsibility for such compliance. * * This code was written as part of the LinucCNC HAL project. For more * information, go to www.linuxcnc.org. */ component gears "A component used to detect the current gear of a lathe and prompts the user to select the correct gear"; description " This component looks at the requested spindle speed as well as the actual spindle speed and \ determines that the correct gears is used for constant surface speed cutting on a lathe. \ If the gear is not correct it will not turn on the spindle-at-speed signal and turn off the \ spindle. It will indicate what gear should be selected for the required speed. The information \ for selecting gears is obtained from a list of speed ranges for each gear. \ \ The function will start the spindle at the higest possible speed and with the higest gain setting \ to try and achieved the requested maximum speed. It will hunt up the gear settings until it finds the \ required gear setting. If the current gear does not match the required gear, then the spindle will stop \ and the indicator will show the required gear. Once the user has selected the correct pulley or gear \ they push the go button and the system will test the gear again. If it finds the correct gear was selected, \ the output signal will be scaled to match the full speed of the selected gear." ; author "Marius D. Liebenberg"; //option singleton yes; //option default_count = 1; //option userspace yes; // Input Pins pin in float spindle_cmd_in ; pin in float spindle_fb_in ; pin in float spindle_req_max "set this parameter in the gcode file- g96(xxx)"; pin in bit spindle_en_in ; pin in bit timer_off ; pin in bit go_btn ; // Output Pins pin out float spindle_cmd_out = 0.0; pin out float spindle_fb_out ; pin out float spindle_gain_out; pin out float time_delay ; pin out s32 gear_curr ; pin out s32 gear_req ; pin out bit spindle_at_speed_out ; pin out bit spindle_en_out ; pin out bit timer_on ; // Parameters param rw s32 gear_max_0#[6] "maximum rpm for every gear"; param rw s32 gear_min_0#[6] "minimum rpm for every gear"; param rw s32 gear_delay_0#[6] "motor startup and stop delay for every gear"; param rw float spindle_gain_0#[6] "spindle gain for each gear selected"; param rw s32 rpm_tol = 10 ; param rw float spindle_max_gain "base gain to achiev max rpm. 0-10v = 2250rpm"; param rw float spindle_max "maximum rpm of the spindle"; // Global Variables variable float var ; variable unsigned process; variable bool new_process = 0; variable unsigned current_gear = 5; variable unsigned next_state; variable unsigned i = 0; variable unsigned x = 0; license "GPL"; function _; ;; enum state { eIdle = 0, eStart = 1, eStart_delay = 2, eCheck_rpm = 3, eCalc_gear = 4, eStop_delay = 5, eWait_for_go = 6, eRunning = 7 }; #include "rtapi_math.h" FUNCTION(_) { if (spindle_en_in == 1) { if (new_process == 1) { process = eStart; new_process = false; } switch(process) { case eIdle: new_process = true; break; case eStart: spindle_gain_out = spindle_max_gain; // set gain for full drive spindle_cmd_out = spindle_max; // run spindle at full speed spindle_en_out = 1; process = eStart_delay; next_state = eCalc_gear; break; case eCalc_gear : while (spindle_req_max < gear_max_0(i)){i++;} // seek upwards until the rpm is bigger while (spindle_req_max > gear_min_0(i)){i--;} // seek down until rpm is smaller gear_req = x; while (spindle_fb_in < gear_max_0(i)){i++;} // seek upwards until the rpm is bigger while (spindle_fb_in > gear_min_0(i)){i--;} // seek down until rpm is smaller current_gear = i; // the gear is found gear_curr = current_gear; if (gear_curr != gear_req) { spindle_cmd_out = 0; spindle_en_out = false; process = eStart_delay; next_state = eWait_for_go; spindle_at_speed_out = false; }else { spindle_gain_out = spindle_gain_0(current_gear); spindle_at_speed_out = true; process = eRunning; } break; case eWait_for_go : if (go_btn == true) { process = eStart; } break; case eStart_delay : time_delay = gear_delay_0(current_gear); // set the time delay for current gear if (timer_on == 0) // if the timer was tripped already do nothing { timer_on = 1; // else trip the timer } if (timer_off == 1) // if the timer has timed out { timer_on = 0; // remove the trip time_delay = 0; process = next_state; // return to the caller of the time delay } break; case eRunning : spindle_cmd_out = spindle_cmd_in; spindle_fb_out = spindle_fb_in; break; default : process = eIdle; break; } }else { process = eIdle; new_process = true; } }