Following error - Rotary Axis

I'm getting a following error on Joint 4 (A Axis) when running the following section of gcode on my fixed gantry machine + rotary axis.

I've read through myriad of threads and I can't figure out how to fix it!  Any help would be greatly appreciated.

INI and HAL files attached.

Gcode:
I get a following error on the line that starts with G1 A-720.

Few more details that may be important - this is a machine with open loop steppers...from other threads I've read...2 things cause following error message:

1) Stepgen velocity and stepgen accel not having enough "headroom" over the axis valuse
2) The base thread rate not actually being able to make all the requested pulses.

But I think I'm good on this front? My Base_Thread = 50000ns, which should allow for 10000 steps/sec....well above what my ini files specify.

You should not have a base thread at all with a Mesa configuration...

Right - yep, agree. After doing some pretty good searching over the last couple days, I found that BASE_PERIOD does nothing on Mesa configs. If you look at the HAL config, nothing is tied to the base thread anyway, so I don't think it had any effect.

Anyway, I remove the BASE_PERIOD from the .ini today, and tried again, and I still get a following error on Joint 4 at the same place in the G-code file.

Anything else I can try and scope to try and figure this out?  Do my FERROR and MIN_FERROR values look good in the .ini?  I can't even figure out where those values play in as I can't find those params referenced in the HAL file.

Updated INI and HAL files attached.

This is what halscope shows right when the following error occurs:
 

Updating here for posterity...I guess it really was as simple as an update to the STEPGEN_MAXVEL and STEPGEN_MAXACCEL values.

This fixed the issue immediately.

Before:
STEPGEN_MAXVEL = 450
STEPGEN_MAXACCEL = 1250

After:
STEPGEN_MAXVEL = 600
STEPGEN_MAXACCEL = 1500

 

The original values in the ini file should be OK
(stepgen velocity and accel values are 25% > than
the joint/axis limits)

Can you plot the joint velocity along with the following
error (with the original ini file values) to see
what's gone wrong?

Thanks for the note - I am interested in troubleshooting more just to learn more...

I'll do some more testing this evening and report back.

Here's a plot with joint.4.vel-cmd as well...that was the only signal I could find that was joint velocity.

 

Same plot, but with:
STEPGEN_MAXVEL = 600
STEPGEN_MAXACCEL = 1500

 

If you look at the slope of the velocity,
the acceleration on the fast velocity downslope
exceeds 1500 deg/s^2, causing the increasing
following error because the stepgen is not allowed
to accelerate beyond 1500 deg/s^2.

So this seems like a trajectory planner or ini setup issue.