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2.9.3 - Stuck in wrong state and stops

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20 Mar 2025 06:09 #324339 by rodw
2.9.3 - Stuck in wrong state and stops was created by rodw
Reported by a customer. Sometimes, QTP freezes. Moving the float switch by hand seems to clear the error and the cut proceeds.
Any ideas or feedback? I have never experienced this.
I wanted to write a script that updates APT to look at the new Buildbot for 2.10 instead of the Linuxcnc.org 2.94  repo so it looks like I need to do that now....
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21 Mar 2025 01:45 #324393 by tommylight
Replied by tommylight on topic 2.9.3 - Stuck in wrong state and stops
Any news on this?
What exactly happens, if you got more feedback?
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Last i actually used it for work (not just testing) QTP was over a year ago (when Debian 12.3 was released), it still had a nasty habit of getting stuck doing nothing as follows:
-usually does any number of cuts ok then it hangs on torch going up and does nothing at all, did not try the switch thing so not sure if this is the same issue, but i did notice the Z axis would not go all the way to the top safe travel height, usually 1-3mm lower, only stopping the execution and running from line would work for me.
The same thing happened on PlasmaC and Phill fixed it, so it is strange that it happens on QTP but not on PlasmaC....well it did happen on PlasmaC, about once in 6-9 months of daily use, while on QTP it would happen daily, several times a day sometimes, then it would not happen for months, then happen again.....
Hence i do not use it on production machines.
-
I wrote a rant here and deleted it...
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22 Mar 2025 21:35 #324587 by snowgoer540
Replied by snowgoer540 on topic 2.9.3 - Stuck in wrong state and stops

The same thing happened on PlasmaC and Phill fixed it, so it is strange that it happens on QTP but not on PlasmaC....well it did happen on PlasmaC, about once in 6-9 months of daily use, while on QTP it would happen daily, several times a day sometimes, then it would not happen for months, then happen again.....
Hence i do not use it on production machines.
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I wrote a rant here and deleted it...


Rants don't usually help ... however configuration backups (made from the settings tab) sometimes do. It's hard to diagnose otherwise since Phill, nor I, nor a guy who cut so much plate with QtPlasmaC he was able to sell his plasma table and buy a large fiber laser have seen this issue.

Also, adding the following to your postgui.hal file might help see where it gets stuck as well:
setp plasmac.debug-print 1

Lastly, it's worth noting that plasmac, plasmac2, and qtplasmac all use the same plasmac component at least to the extent where anything fixed in the original PlasmaC was carried forward to the same PlasmaC component today.

If there's a bug, no one wants to find it more than me, but it’s really challenging to identify a bug without being able to reproduce it. Can't squish a bug I can't see :)
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22 Mar 2025 22:19 #324589 by rodw
Replied by rodw on topic 2.9.3 - Stuck in wrong state and stops
More feedback here. Customer has an IT savvy brother. His brother told him to lift the torch to clear the stall after reviewing the code and it worked!
It goes without saying, I have asked for a line number reference. :)

I think this implies the bug lurks in the plasmac.comp state machine somewhere.

I've already found my plasmac bug for the day. Maybe someone elses turn!
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23 Mar 2025 02:05 #324604 by snowgoer540
Replied by snowgoer540 on topic 2.9.3 - Stuck in wrong state and stops

More feedback here. Customer has an IT savvy brother. His brother told him to lift the torch to clear the stall after reviewing the code and it worked!
It goes without saying, I have asked for a line number reference. :)

I think this implies the bug lurks in the plasmac.comp state machine somewhere.

I've already found my plasmac bug for the day. Maybe someone elses turn!


Provided the works was not completely locked up, float activation, torch breakaway, ohmic detection, or arc ok lost will always result in a program pause which should break up any state hangs.

That check (during a running program) begins at line 691. What would be more useful would be to know what state it was in when it "freezes".

That could be seen by running QtPlasmaC from a terminal, and either using Halshow to change plasmac.debug-print True, or having already added
setp plasmac.debug-print 1
to the postgui.hal file. Watch the terminal for the state it freezes in.

A backup of the config from the Settings tab may help too.
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23 Mar 2025 07:44 #324632 by rodw
Replied by rodw on topic 2.9.3 - Stuck in wrong state and stops
Thanks, given that this issue only happens once a week or so, is the output logged anywhere?
This table gets some pretty heavy use so maybe it will be a good candidate for finding bugs.
Its probably not 100% current but the config is here
github.com/rodw-au/showstopper

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23 Mar 2025 13:40 #324664 by snowgoer540
Replied by snowgoer540 on topic 2.9.3 - Stuck in wrong state and stops

Thanks, given that this issue only happens once a week or so, is the output logged anywhere?


Not other than the terminal. I spent 5-10 minutes confirming my suspicion that the mismatch in timing between the GUI and the component is such that catching the state changes at a GUI level is fruitless. Even appending them to a variable and writing that to the log file when the machine goes IDLE again reveals that it misses some state changes. I'd be reluctant to add file based logging to the component.

Not sure where the harm would be in running from the terminal, and turning on debug-print and then having your customer look at the terminal window the next time it "freezes" and report back on the last state displayed.

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23 Mar 2025 13:44 #324665 by snowgoer540
Replied by snowgoer540 on topic 2.9.3 - Stuck in wrong state and stops
Here is what it looked like:  

 

For reference:
        # plasmac states
        self.IDLE           =  0
        self.PROBE_HEIGHT   =  1
        self.PROBE_DOWN     =  2
        self.PROBE_UP       =  3
        self.ZERO_HEIGHT    =  4
        self.PIERCE_HEIGHT  =  5
        self.TORCH_ON       =  6
        self.ARC_OK         =  7
        self.PIERCE_DELAY   =  8
        self.PUDDLE_JUMP    =  9
        self.CUT_HEGHT      = 10
        self.CUT_MODE_01    = 11
        self.CUT_MODE_2     = 12
        self.PAUSE_AT_END   = 13
        self.SAFE_HEIGHT    = 14
        self.MAX_HEIGHT     = 15
        self.END_CUT        = 16
        self.END_JOB        = 17
        self.TORCH_PULSE    = 18
        self.PAUSED_MOTION  = 19
        self.OHMIC_TEST     = 20
        self.PROBE_TEST     = 21
        self.SCRIBING       = 22
        self.CONS_CHNG_ON   = 23
        self.CONS_CHNG_OFF  = 24
        self.CUT_REC_ON     = 25
        self.CUT_REC_OFF    = 26
        self.DEBUG          = 27

So it missed:
4 - ZERO_HEIGHT
14 - SAFE_HEIGHT
16 - END_CUT
17- END_JOB
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24 Mar 2025 02:49 #324720 by rodw
Replied by rodw on topic 2.9.3 - Stuck in wrong state and stops
I received additional detailed information from the customer and have raised an issue in github here
github.com/LinuxCNC/linuxcnc/issues/3382
Hopefully, this can be resolved.

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24 Mar 2025 04:51 #324725 by phillc54
Replied by phillc54 on topic 2.9.3 - Stuck in wrong state and stops
Is there a complete sim config somewhere that can be used to test for this issue?
If so I can probably make a bit time to have a look.

The config posted above is not a sim but a quick glance does show a couple of oddities in runstep.hal:
# External Program Pause/Resume and Run/Step Buttons
# Pause/Resume Section
unlinkp halui.program.is-paused
unlinkp halui.program.is-running
net plasmac:program-is-paused => pr-or2.in0
net ispaused halui.program.is-paused => pr-or2.in1
net plasmac:program-is-running => pr-or3.in0
The two plasma:program-is-... signals seem to have nothing driving them, just two inputs connected together.

Have you thought of using the provided external button pins?

 

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