Pesky "following error"s with Mesa 7c81

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3 years 6 months ago #268760 by TallGuy
Sorry, I hoped to resolve this issue myself but I can't seem to get to grips with it.

I've converted an SX2P with Pi4, Mesa 7c81 and an eBay 5 axis Bob, feeding motor controllers and steppers from cnc4you.co.uk.

I keep getting the infamous "following errors" on all joints. I have wondered if this is because pncconf sets things up for servos rather than steppers?
The errors can come very quickly, sometimes when the head is stationary, or it can lull me into a false sense of security and take a while to pop up.
I also experience watchdog errors sometimes.

Linux 5,4.83-rt48-v71+, LinuxCNC 2.8.4 

I've obviously for something or some things very wrong but I'm stuck :/

Thanks in advance for your help!
Code:
# Generated by PNCconf at Sun Jan  8 17:08:56 2023 # Using LinuxCNC version:  2.8 # If you make changes to this file, they will be # overwritten when you run PNCconf again [EMC] MACHINE = Milling_machine DEBUG = 0 VERSION = 1.1 [DISPLAY] DISPLAY = axis POSITION_OFFSET = RELATIVE POSITION_FEEDBACK = ACTUAL MAX_FEED_OVERRIDE = 2.000000 MAX_SPINDLE_OVERRIDE = 1.000000 MIN_SPINDLE_OVERRIDE = 0.500000 INTRO_GRAPHIC = linuxcnc.gif INTRO_TIME = 5 PROGRAM_PREFIX = /mnt/filestore INCREMENTS = 5mm 1mm .5mm .1mm .05mm .01mm .005mm POSITION_FEEDBACK = ACTUAL DEFAULT_LINEAR_VELOCITY = 6.000000 MAX_LINEAR_VELOCITY = 25.000000 MIN_LINEAR_VELOCITY = 0.500000 DEFAULT_ANGULAR_VELOCITY = 12.000000 MAX_ANGULAR_VELOCITY = 180.000000 MIN_ANGULAR_VELOCITY = 1.666667 EDITOR = gedit GEOMETRY = xyz [FILTER] PROGRAM_EXTENSION = .png,.gif,.jpg Greyscale Depth Image PROGRAM_EXTENSION = .py Python Script png = image-to-gcode gif = image-to-gcode jpg = image-to-gcode py = python [TASK] TASK = milltask CYCLE_TIME = 0.010 [RS274NGC] PARAMETER_FILE = linuxcnc.var RS274NGC_STARTUP_CODE = G21 G40 G90 G94 G97 G64 P0.025 [EMCMOT] EMCMOT = motmod COMM_TIMEOUT = 1.0 SERVO_PERIOD = 1000000 [HMOT] CARD0=hm2_7c81.0 [HAL] HALUI = halui HALFILE = Milling_machine.hal HALFILE = custom.hal POSTGUI_HALFILE = postgui_call_list.hal SHUTDOWN = shutdown.hal [HALUI] [KINS] JOINTS = 3 KINEMATICS = trivkins coordinates=XYZ [TRAJ] COORDINATES =  XYZ LINEAR_UNITS = mm ANGULAR_UNITS = degree DEFAULT_LINEAR_VELOCITY = 2.50 MAX_LINEAR_VELOCITY = 25.00 NO_FORCE_HOMING = 1 [EMCIO] EMCIO = io CYCLE_TIME = 0.100 TOOL_TABLE = tool.tbl TOOL_CHANGE_QUILL_UP = 1 #****************************************** [AXIS_X] MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 MIN_LIMIT = -0.01 MAX_LIMIT = 200.0 [JOINT_0] TYPE = LINEAR HOME = 0.0 FERROR = 10.0 MIN_FERROR = 1.0 MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 # The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION # If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger. STEPGEN_MAXVEL = 31.25 STEPGEN_MAXACCEL = 937.5 P = 1000.0 I = 0.0 D = 0.0 FF0 = 0.0 FF1 = 1.0 FF2 = 0.0 BIAS = 0.0 DEADBAND = 0.0 MAX_OUTPUT = 0.0 # these are in nanoseconds DIRSETUP   = 10000 DIRHOLD    = 10000 STEPLEN    = 5000 STEPSPACE  = 5000 STEP_SCALE=500 MIN_LIMIT = -0.01 MAX_LIMIT = 200.0 HOME_OFFSET = 0.000000 HOME_SEARCH_VEL = -1.000000 HOME_LATCH_VEL = -0.500000 HOME_FINAL_VEL = 0.000000 HOME_USE_INDEX = NO HOME_SEQUENCE = 1 #****************************************** #****************************************** [AXIS_Y] MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 MIN_LIMIT = -0.01 MAX_LIMIT = 200.0 [JOINT_1] TYPE = LINEAR HOME = 0.0 FERROR = 10.0 MIN_FERROR = 1.0 MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 # The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION # If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger. STEPGEN_MAXVEL = 31.25 STEPGEN_MAXACCEL = 937.5 P = 1000.0 I = 0.0 D = 0.0 FF0 = 0.0 FF1 = 1.0 FF2 = 0.0 BIAS = 0.0 DEADBAND = 0.0 MAX_OUTPUT = 0.0 # these are in nanoseconds DIRSETUP   = 10000 DIRHOLD    = 10000 STEPLEN    = 5000 STEPSPACE  = 5000 STEP_SCALE=-500 MIN_LIMIT = -0.01 MAX_LIMIT = 200.0 HOME_OFFSET = 0.000000 HOME_SEARCH_VEL = -1.000000 HOME_LATCH_VEL = -0.500000 HOME_FINAL_VEL = 0.000000 HOME_USE_INDEX = NO HOME_SEQUENCE = 2 #****************************************** #****************************************** [AXIS_Z] MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 MIN_LIMIT = -100.0 MAX_LIMIT = 0.01 [JOINT_2] TYPE = LINEAR HOME = 0.0 FERROR = 10.0 MIN_FERROR = 1.0 MAX_VELOCITY = 25.0 MAX_ACCELERATION = 750.0 # The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION # If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger. STEPGEN_MAXVEL = 31.25 STEPGEN_MAXACCEL = 937.5 P = 1000.0 I = 0.0 D = 0.0 FF0 = 0.0 FF1 = 1.0 FF2 = 0.0 BIAS = 0.0 DEADBAND = 0.0 MAX_OUTPUT = 0.0 # these are in nanoseconds DIRSETUP   = 10000 DIRHOLD    = 10000 STEPLEN    = 5000 STEPSPACE  = 5000 # STEP_SCALE = 100.0 STEP_SCALE=1000.0 MIN_LIMIT = -100.0 MAX_LIMIT = 0.01 HOME_OFFSET = 0.000000 HOME_SEARCH_VEL = -1.000000 HOME_LATCH_VEL = -0.500000 HOME_FINAL_VEL = 0.000000 HOME_USE_INDEX = NO HOME_SEQUENCE = 0 #******************************************
 
Code:
# Generated by PNCconf at Sun Jan  8 17:08:56 2023 # Using LinuxCNC version:  2.8 # If you make changes to this file, they will be # overwritten when you run PNCconf again loadrt [KINS]KINEMATICS loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[KINS]JOINTS loadrt hostmot2 loadrt hm2_rpspi config="num_encoders=0 num_pwmgens=1 num_stepgens=5"  setp    [HMOT](CARD0).pwmgen.pwm_frequency 20000 setp    [HMOT](CARD0).pwmgen.pdm_frequency 6000000 setp    [HMOT](CARD0).watchdog.timeout_ns 10000000 loadrt pid names=pid.x,pid.y,pid.z,pid.s addf [HMOT](CARD0).read          servo-thread addf motion-command-handler   servo-thread addf motion-controller        servo-thread addf pid.x.do-pid-calcs       servo-thread addf pid.y.do-pid-calcs       servo-thread addf pid.z.do-pid-calcs       servo-thread addf pid.s.do-pid-calcs       servo-thread addf [HMOT](CARD0).write         servo-thread # ---Chargepump StepGen: 0.25 velocity = 10Khz square wave output--- setp   [HMOT](CARD0).stepgen.04.dirsetup        100 setp   [HMOT](CARD0).stepgen.04.dirhold         100 setp   [HMOT](CARD0).stepgen.04.steplen         100 setp   [HMOT](CARD0).stepgen.04.stepspace       100 setp   [HMOT](CARD0).stepgen.04.position-scale  10000 setp   [HMOT](CARD0).stepgen.04.step_type       2 setp   [HMOT](CARD0).stepgen.04.control-type    1 setp   [HMOT](CARD0).stepgen.04.maxaccel        0 setp   [HMOT](CARD0).stepgen.04.maxvel          0 setp   [HMOT](CARD0).stepgen.04.velocity-cmd    0.25 net x-enable                                 => [HMOT](CARD0).stepgen.04.enable # external output signals # external input signals # --- HOME-X --- net home-x     <=  [HMOT](CARD0).gpio.013.in # --- HOME-Y --- net home-y     <=  [HMOT](CARD0).gpio.014.in # --- HOME-Z --- net home-z     <=  [HMOT](CARD0).gpio.015.in #******************* #  AXIS X JOINT 0 #******************* setp   pid.x.Pgain     [JOINT_0]P setp   pid.x.Igain     [JOINT_0]I setp   pid.x.Dgain     [JOINT_0]D setp   pid.x.bias      [JOINT_0]BIAS setp   pid.x.FF0       [JOINT_0]FF0 setp   pid.x.FF1       [JOINT_0]FF1 setp   pid.x.FF2       [JOINT_0]FF2 setp   pid.x.deadband  [JOINT_0]DEADBAND setp   pid.x.maxoutput [JOINT_0]MAX_OUTPUT setp   pid.x.error-previous-target true # This setting is to limit bogus stepgen # velocity corrections caused by position # feedback sample time jitter. setp   pid.x.maxerror 0.012700 net x-index-enable  => pid.x.index-enable net x-enable        =>  pid.x.enable net x-pos-cmd       =>  pid.x.command net x-pos-fb        =>  pid.x.feedback net x-output        <=  pid.x.output # Step Gen signals/setup setp   [HMOT](CARD0).stepgen.00.dirsetup        [JOINT_0]DIRSETUP setp   [HMOT](CARD0).stepgen.00.dirhold         [JOINT_0]DIRHOLD setp   [HMOT](CARD0).stepgen.00.steplen         [JOINT_0]STEPLEN setp   [HMOT](CARD0).stepgen.00.stepspace       [JOINT_0]STEPSPACE setp   [HMOT](CARD0).stepgen.00.position-scale  [JOINT_0]STEP_SCALE setp   [HMOT](CARD0).stepgen.00.step_type        0 setp   [HMOT](CARD0).stepgen.00.control-type     1 setp   [HMOT](CARD0).stepgen.00.maxaccel         [JOINT_0]STEPGEN_MAXACCEL setp   [HMOT](CARD0).stepgen.00.maxvel           [JOINT_0]STEPGEN_MAXVEL # ---closedloop stepper signals--- net x-pos-cmd    <= joint.0.motor-pos-cmd net x-vel-cmd    <= joint.0.vel-cmd net x-output     => [HMOT](CARD0).stepgen.00.velocity-cmd net x-pos-fb     <= [HMOT](CARD0).stepgen.00.position-fb net x-pos-fb     => joint.0.motor-pos-fb net x-enable     <= joint.0.amp-enable-out net x-enable     => [HMOT](CARD0).stepgen.00.enable # ---setup home / limit switch signals--- net home-x     =>  joint.0.home-sw-in net x-neg-limit     =>  joint.0.neg-lim-sw-in net x-pos-limit     =>  joint.0.pos-lim-sw-in #******************* #  AXIS Y JOINT 1 #******************* setp   pid.y.Pgain     [JOINT_1]P setp   pid.y.Igain     [JOINT_1]I setp   pid.y.Dgain     [JOINT_1]D setp   pid.y.bias      [JOINT_1]BIAS setp   pid.y.FF0       [JOINT_1]FF0 setp   pid.y.FF1       [JOINT_1]FF1 setp   pid.y.FF2       [JOINT_1]FF2 setp   pid.y.deadband  [JOINT_1]DEADBAND setp   pid.y.maxoutput [JOINT_1]MAX_OUTPUT setp   pid.y.error-previous-target true # This setting is to limit bogus stepgen # velocity corrections caused by position # feedback sample time jitter. setp   pid.y.maxerror 0.012700 net y-index-enable  => pid.y.index-enable net y-enable        =>  pid.y.enable net y-pos-cmd       =>  pid.y.command net y-pos-fb        =>  pid.y.feedback net y-output        <=  pid.y.output # Step Gen signals/setup setp   [HMOT](CARD0).stepgen.01.dirsetup        [JOINT_1]DIRSETUP setp   [HMOT](CARD0).stepgen.01.dirhold         [JOINT_1]DIRHOLD setp   [HMOT](CARD0).stepgen.01.steplen         [JOINT_1]STEPLEN setp   [HMOT](CARD0).stepgen.01.stepspace       [JOINT_1]STEPSPACE setp   [HMOT](CARD0).stepgen.01.position-scale  [JOINT_1]STEP_SCALE setp   [HMOT](CARD0).stepgen.01.step_type        0 setp   [HMOT](CARD0).stepgen.01.control-type     1 setp   [HMOT](CARD0).stepgen.01.maxaccel         [JOINT_1]STEPGEN_MAXACCEL setp   [HMOT](CARD0).stepgen.01.maxvel           [JOINT_1]STEPGEN_MAXVEL # ---closedloop stepper signals--- net y-pos-cmd    <= joint.1.motor-pos-cmd net y-vel-cmd    <= joint.1.vel-cmd net y-output     => [HMOT](CARD0).stepgen.01.velocity-cmd net y-pos-fb     <= [HMOT](CARD0).stepgen.01.position-fb net y-pos-fb     => joint.1.motor-pos-fb net y-enable     <= joint.1.amp-enable-out net y-enable     => [HMOT](CARD0).stepgen.01.enable # ---setup home / limit switch signals--- net home-y     =>  joint.1.home-sw-in net y-neg-limit     =>  joint.1.neg-lim-sw-in net y-pos-limit     =>  joint.1.pos-lim-sw-in #******************* #  AXIS Z JOINT 2 #******************* setp   pid.z.Pgain     [JOINT_2]P setp   pid.z.Igain     [JOINT_2]I setp   pid.z.Dgain     [JOINT_2]D setp   pid.z.bias      [JOINT_2]BIAS setp   pid.z.FF0       [JOINT_2]FF0 setp   pid.z.FF1       [JOINT_2]FF1 setp   pid.z.FF2       [JOINT_2]FF2 setp   pid.z.deadband  [JOINT_2]DEADBAND setp   pid.z.maxoutput [JOINT_2]MAX_OUTPUT setp   pid.z.error-previous-target true # This setting is to limit bogus stepgen # velocity corrections caused by position # feedback sample time jitter. setp   pid.z.maxerror 0.012700 net z-index-enable  => pid.z.index-enable net z-enable        =>  pid.z.enable net z-pos-cmd       =>  pid.z.command net z-pos-fb        =>  pid.z.feedback net z-output        <=  pid.z.output # Step Gen signals/setup setp   [HMOT](CARD0).stepgen.02.dirsetup        [JOINT_2]DIRSETUP setp   [HMOT](CARD0).stepgen.02.dirhold         [JOINT_2]DIRHOLD setp   [HMOT](CARD0).stepgen.02.steplen         [JOINT_2]STEPLEN setp   [HMOT](CARD0).stepgen.02.stepspace       [JOINT_2]STEPSPACE setp   [HMOT](CARD0).stepgen.02.position-scale  [JOINT_2]STEP_SCALE setp   [HMOT](CARD0).stepgen.02.step_type        0 setp   [HMOT](CARD0).stepgen.02.control-type     1 setp   [HMOT](CARD0).stepgen.02.maxaccel         [JOINT_2]STEPGEN_MAXACCEL setp   [HMOT](CARD0).stepgen.02.maxvel           [JOINT_2]STEPGEN_MAXVEL # ---closedloop stepper signals--- net z-pos-cmd    <= joint.2.motor-pos-cmd net z-vel-cmd    <= joint.2.vel-cmd net z-output     => [HMOT](CARD0).stepgen.02.velocity-cmd net z-pos-fb     <= [HMOT](CARD0).stepgen.02.position-fb net z-pos-fb     => joint.2.motor-pos-fb net z-enable     <= joint.2.amp-enable-out net z-enable     => [HMOT](CARD0).stepgen.02.enable # ---setup home / limit switch signals--- net home-z     =>  joint.2.home-sw-in net z-neg-limit     =>  joint.2.neg-lim-sw-in net z-pos-limit     =>  joint.2.pos-lim-sw-in #****************************** # connect miscellaneous signals #****************************** #  ---HALUI signals--- net axis-select-x  halui.axis.x.select net jog-x-pos      halui.axis.x.plus net jog-x-neg      halui.axis.x.minus net jog-x-analog   halui.axis.x.analog net x-is-homed     halui.joint.0.is-homed net axis-select-y  halui.axis.y.select net jog-y-pos      halui.axis.y.plus net jog-y-neg      halui.axis.y.minus net jog-y-analog   halui.axis.y.analog net y-is-homed     halui.joint.1.is-homed net axis-select-z  halui.axis.z.select net jog-z-pos      halui.axis.z.plus net jog-z-neg      halui.axis.z.minus net jog-z-analog   halui.axis.z.analog net z-is-homed     halui.joint.2.is-homed net jog-selected-pos      halui.axis.selected.plus net jog-selected-neg      halui.axis.selected.minus net spindle-manual-cw     halui.spindle.0.forward net spindle-manual-ccw    halui.spindle.0.reverse net spindle-manual-stop   halui.spindle.0.stop net machine-is-on         halui.machine.is-on net jog-speed             halui.axis.jog-speed net MDI-mode              halui.mode.is-mdi #  ---coolant signals--- net coolant-mist      <=  iocontrol.0.coolant-mist net coolant-flood     <=  iocontrol.0.coolant-flood #  ---probe signal--- net probe-in     =>  motion.probe-input #  ---motion control signals--- net in-position               <=  motion.in-position net machine-is-enabled        <=  motion.motion-enabled #  ---digital in / out signals--- #  ---estop signals--- net estop-out     <=  iocontrol.0.user-enable-out net estop-out     =>  iocontrol.0.emc-enable-in #  ---manual tool change signals--- loadusr -W hal_manualtoolchange net tool-change-request     iocontrol.0.tool-change       =>  hal_manualtoolchange.change net tool-change-confirmed   iocontrol.0.tool-changed      <=  hal_manualtoolchange.changed net tool-number             iocontrol.0.tool-prep-number  =>  hal_manualtoolchange.number net tool-prepare-loopback   iocontrol.0.tool-prepare      =>  iocontrol.0.tool-prepared
 

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3 years 6 months ago #268761 by PCW
If you get a following error when not in motion, that suggests a data integrity error
This may be because of a too long cable between the RPI and the 7C81.
1.5" max cable length is suggested, or a cable without all pins used (all RPI GND
and power pins are  used for AC ground to prevent ground bumping.)

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3 years 6 months ago #268765 by TallGuy
Ah that is interesting. It is a full cable but it's 20cm (almost 8") from eusurplus.

I'll fix that - thank you and fingers crossed!

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