Hurco BMC20 Dynomotion Retrofit

[TomKerekes]

Hi Troy,

The code still needs cleaned up and some adjustments made, like a way to wait for spindle to come to a complete stop before starting Tool Change sequence, other than a delay. Example: If spindle was running at 3800RPM the delay needs to be about 8seconds for spindle to come to a complete stop. But if RPM was at 500RPM the delay needs to be much less.

I believe your Spindle has an encoder so you might wait until the measured speed is close enough to zero (or your desired speed). Note exactly zero speed might not occur in some cases if there is something like the slightest dither in the spindle position. So you might do something like:

while (fast_fabs(Spindle.TrueSpeedRPS)*60.0 > 5.0) ; // wait until less than 5RPM

Waiting for video

[Need TECH Help!]

Hi Tom,
That did the trick I also added it to my M5 code. Will get a video soon. Would like to fix an air cushion issue for cylinder that extends and retracts the tool changer, before i post a video. Currently is slamming when it retracts.Using some rubber stops to absorb shock now, but it still hits hard. The cushion screw is having very little effect. Thinking will need to disassemble the cylinder.
But still never thought a working tool changer would make me this happy.
Thanks,
Troy

[Need TECH Help!]

.......

And here is the code to read file from disk. Put this in your init file, before forever loop. You may need to create that file first, make sure paths match up. Mine is just a txt file with the tool number in it. Mine has 6 decimal places, not sure if it makes a difference. Currently says 16.000000

FILE *f;
    	char s[256];
	double CTool=0;
	int result;

    	f=fopen("c:\\KMotion Files\\KFlopData.txt","rt");
    	if (!f)
    	{
       	 printf("Unable to open file\n");
        	return;
    	}
    	result=fscanf(f,"%lf",&CTool);
    	fclose(f);    
	persist.UserData[157] = CTool;
	printf("Current tool=%f\n",CTool);

	// Send MDI code to kmotion to display proper tool
	char s[80];
   	sprintf(s,"T%d",persist.UserData[157]);
	MDI(s);  //send the T word

Hi mmurray,
Iam getting an error when compiling. States that 'f' is undeclared. How and where should it be defined? In the main init code or ?

Thanks,
Troy

[mmurray70]

Troy,

I had a look through my init file and dont see anything else about that f being declared. Pretty sure that is everything. The first line is not indented in my init like it shows here on the forum, all lines are even with each other, but I doubt that will change anything. Maybe Tom can help with this.

I think your air cylinder is probably fine. In order to retract smoothly, the backside of the cylinder needs to be pressurized up until the point of when you want to reverse it. Their needs to be air on the backside in order for the motion to be dampened. Looking at your code, you set a bit to extend the cylinder and then clear it. Leave that bit on until the new tool is loaded and when your ready to retract, turn that bit off, and switch the other one on. It will retract much smoother that way, and the cusion screw should do its job. Does it extend smoothly? The extending part would probably be smoother as well if there was pressure on the other end before extending. Id probably have your init file pressurize the cylinder to retract on start up, and always leave one side pressurized. Just get your toolchange program to switch back and forth. Make it operate the same as a 2 position solenoid valve. Always extending or retracting, never in neutral.

I learned this from an ameria seiki VMC at my last shop. It had a side mount tool changer, and the arm that tilted tool 90 degrees had a 3 position solenoid valve from the factory, with neutral (held pressure in cyl) in the middle. If the machine was sitting for an hour or more the cylinder would have lost its pressue and then when you did a toolchange it would slam down hard sometimes dropping the tool, first toolchange of the day was also the same. I changed it to a 2 positon valve with no neutral and problem solved. Smooth as silk every time.

Mark

[TomKerekes]

Hi Troy,

Hi mmurray,
Iam getting an error when compiling. States that 'f' is undeclared. How and where should it be defined? In the main init code or ?

I had a look through my init file and dont see anything else about that f being declared. Pretty sure that is everything. The first line is not indented in my init like it shows here on the forum, all lines are even with each other, but I doubt that will change anything. Maybe Tom can help with this.

The code FILE *f; should define 'f' and it shouldn't matter if it is indented or not. The compiler ignores 'white space'. Indenting properly just makes it easier for a human to read and understand. Other minor things are that Result is declared but never used and s is defined twice. But the code you posted compiles ok for me. Here is it cleaned up and indented properly:

    FILE *f;
    double CTool = 0;

    f = fopen("c:\\KMotion Files\\KFlopData.txt", "rt");
    if (!f)
    {
        printf("Unable to open file\n");
        return;
    }
    fscanf(f, "%lf", &CTool);
    fclose(f);
    persist.UserData[157] = CTool;
    printf("Current tool=%f\n", CTool);

    // Send MDI code to kmotion to display proper tool
    char s[80];
    sprintf(s, "T%d", persist.UserData[157]);
    MDI(s);                        //send the T word

[Need TECH Help!]

Troy,

......
I think your air cylinder is probably fine. In order to retract smoothly, the backside of the cylinder needs to be pressurized up until the point of when you want to reverse it. Their needs to be air on the backside in order for the motion to be dampened. Looking at your code, you set a bit to extend the cylinder and then clear it. Leave that bit on until the new tool is loaded and when your ready to retract, turn that bit off, and switch the other one on. It will retract much smoother that way, and the cusion screw should do its job. Does it extend smoothly? The extending part would probably be smoother as well if there was pressure on the other end before extending. Id probably have your init file pressurize the cylinder to retract on start up, and always leave one side pressurized. Just get your toolchange program to switch back and forth. Make it operate the same as a 2 position solenoid valve. Always extending or retracting, never in neutral.

....
Mark

Hi Mark,
I tried this before but has no effect leaving one opposite solenoid on. The air valve will stay maintained keeping air pressure on cylinder no matter what direction. The extension of cylinder is a little softer than retract. The manifold i have all the valves and solenoids attached to has 2 exhaust ports on both sides. Originally i had all for open with mufflers. Then i plugged off 2 and that helped but still not soft like it should be. Once all the C code is working i will work on this some more. As old as the cylinder is, it wont hurt to dissemble and inspect it any how.

Troy

[Need TECH Help!]

I dont know how or where exactly to add code to my main INIT code. I tried to where i thought it should be but when executing the init code, the code just hangs. Now i know what the apprentice iam training at work on the CNCs is feeling like,.... except Gcode is much simpler than Ccode
Wish there was some sort of a GUI for this sort of thing.

Troy

[TomKerekes]

Hi Troy,

I tried this before but has no effect leaving one opposite solenoid on. The air valve will stay maintained keeping air pressure on cylinder no matter what direction. The extension of cylinder is a little softer than retract. The manifold i have all the valves and solenoids attached to has 2 exhaust ports on both sides. Originally i had all for open with mufflers. Then i plugged off 2 and that helped but still not soft like it should be. Once all the C code is working i will work on this some more. As old as the cylinder is, it wont hurt to dissemble and inspect it any how.

I don't really follow what you guys are saying, but years ago some equipment I worked on had very smooth pneumatic motion. I believe we used Festo cylinders that had like a double throw double pole solenoid valve right at the cylinder. It switched both sides of the cylinder from pressure to vent and vice versa and the vent had a needle valve to control the rate of motion independently each direction.

I dont know how or where exactly to add code to my main INIT code. I tried to where i thought it should be but when executing the init code, the code just hangs.

You might have told us where you put it. A good place might be just before any forever loop you may have. Not inside the forever loop.

[Need TECH Help!]

I tried before and after forever loop, at least i think i did. Here it is before??

//V3- Added LowPass Filter to output.
//V3.1- Removed waylube bit timer
//V3.2-Added Auto Tool Changer Code
#include "KMotionDef.h"
#define TMP 10					// which spare persist to use to transfer data
#include "KflopToKMotionCNCFunctions.c"
#include "AdjustSoftLimits.c"

//#define CYCLESTARTBIT 16
//#define FEEDHOLDBIT 17
#define ESTOP 137
#define MISTCOOLANTBIT 158
#define FLOODCOOLANTBIT 157
//#define SPINDLESTOPBIT 21
//#define SPINDLECWBIT 19
//#define SPINDLECCWBIT 20
#define VFDERRORLINEBIT 138
#define XSDERRORLINEBIT 139
#define YSDERRORLINEBIT 140
#define ZSDERRORLINEBIT 141

#define XMINUSLIMITBIT 1025
#define XPLUSLIMITBIT 1024
#define YMINUSLIMITBIT 1027
#define YPLUSLIMITBIT 1026
#define ZMINUSLIMITBIT 1029
#define ZPLUSLIMITBIT 1028


#define X 0
#define Y 1
#define Z 2

#define QA 1042					// define to which IO bits the AB signals are connected
#define QB 1041

#define TAU 0.08				// smoothness factor (Low Pass Time constant seconds)
#define FINAL_TIME 1.0			// Set final dest after this amount of time with no change

#define MAX_JOG_SPEED_X 510.0	// ipm
#define MAX_JOG_SPEED_Y 510.0	// ipm
#define MAX_JOG_SPEED_Z 510.0	// ipm


void UpdateJogSpeeds(void);
void DoLimitJog(double rate, int cmd);

void ServiceTimerSequence(void);
void ServiceEStop(void);


// function prototypes for compiler
int DoPC(int cmd);
int DoPCFloat(int cmd, float f);
int Debounce(int n, int *cnt, int *last, int *lastsolid);

// state variables for switch debouncing
int flast = 0, flastsolid = -1, fcount = 0;
int ccwlast = 0, ccwlastsolid = -1, ccwcount = 0;
int cwlast = 0, cwlastsolid = -1, cwcount = 0;
int colast = 0, colastsolid = -1, cocount = 0;
int solast = 0, solastsolid = -1, socount = 0;
int xsdelast = 0, xsdelastsolid = -1, xsdecount = 0;
int ysdelast = 0, ysdelastsolid = -1, ysdecount = 0;
int zsdelast = 0, zsdelastsolid = -1, zsdecount = 0;
int vfdelast = 0, vfdelastsolid = -1, vfdecount = 0;
int zmlast = 0, zmlastsolid = -1, zmcount = 0;
int zplast = 0, zplastsolid = -1, zpcount = 0;
int ymlast = 0, ymlastsolid = -1, ymcount = 0;
int yplast = 0, yplastsolid = -1, ypcount = 0;
int xmlast = 0, xmlastsolid = -1, xmcount = 0;
int xplast = 0, xplastsolid = -1, xpcount = 0;
int clast = 0, clastsolid = -1, ccount = 0;
int elast = 0, elastsolid = -1, ecount = 0;
int hlast = 0, hlastsolid = -1, hcount = 0;
int rlast = 0, rlastsolid = -1, rcount = 0;
int zlast = 0, zlastsolid = -1, zcount = 0;

int xpjblast = 0, xpjblastsolid = -1, xpjbcount = 0;



//int Debounce(int n, int *cnt, int *last, int *lastsolid);

main()
{

	InitAux();
	AddKonnect(0, &VirtualBits, VirtualBitsEx);
	int BitA, Change1 = 0, Change2 = 0, DiffX2;
	int PosNoWrap, NewPos, Pos = 0, wraps;
	int InMotion = FALSE, Axis, LastAxis = -1;
	double LastChangeTime = 0, Target, Factor = 0;


#define DROIN 40
	double *pin = (double *)&persist.UserData[(DROIN - 1) * 2];

	int result;
	int Answer;

	ch0->InputMode = ENCODER_MODE;
	ch0->OutputMode = CL_STEP_DIR_MODE;
	ch0->Vel = 270700;
	ch0->Accel = 9.7e+05;
	ch0->Jerk = 10e+06;
	ch0->P = 0;
	ch0->I = 0.003;
	ch0->D = 0;
	ch0->FFAccel = 0;
	ch0->FFVel = 0;
	ch0->MaxI = 400;
	ch0->MaxErr = 200;
	ch0->MaxOutput = 200;
	ch0->DeadBandGain = 0;
	ch0->DeadBandRange = 1;
	ch0->InputChan0 = 0;
	ch0->InputChan1 = 0;
	ch0->OutputChan0 = 12;
	ch0->OutputChan1 = 0;
	ch0->MasterAxis = -1;
	ch0->LimitSwitchOptions = 0x113;
	ch0->LimitSwitchNegBit = 1025;
	ch0->LimitSwitchPosBit = 1024;
	ch0->SoftLimitPos = 1e+09;
	ch0->SoftLimitNeg = -1e+09;
	ch0->InputGain0 = -1;
	ch0->InputGain1 = 1;
	ch0->InputOffset0 = 0;
	ch0->InputOffset1 = 0;
	ch0->OutputGain = -1;
	ch0->OutputOffset = 0;
	ch0->SlaveGain = 1;
	ch0->BacklashMode = BACKLASH_OFF;
	ch0->BacklashAmount = 0;
	ch0->BacklashRate = 0;
	ch0->invDistPerCycle = 1;
	ch0->Lead = 0;
	ch0->MaxFollowingError = 100;
	ch0->StepperAmplitude = 20;

	ch0->iir[0].B0 = 1;
	ch0->iir[0].B1 = 0;
	ch0->iir[0].B2 = 0;
	ch0->iir[0].A1 = 0;
	ch0->iir[0].A2 = 0;

	ch0->iir[1].B0 = 1;
	ch0->iir[1].B1 = 0;
	ch0->iir[1].B2 = 0;
	ch0->iir[1].A1 = 0;
	ch0->iir[1].A2 = 0;

	ch0->iir[2].B0 = 0.000768809;
	ch0->iir[2].B1 = 0.00153762;
	ch0->iir[2].B2 = 0.000768809;
	ch0->iir[2].A1 = 1.92081;
	ch0->iir[2].A2 = -0.923885;


	ch1->InputMode = ENCODER_MODE;
	ch1->OutputMode = CL_STEP_DIR_MODE;
	ch1->Vel = 270700;
	ch1->Accel = 9.7e+05;
	ch1->Jerk = 10e+06;
	ch1->P = 0;
	ch1->I = 0.003;
	ch1->D = 0;
	ch1->FFAccel = 0;
	ch1->FFVel = 0;
	ch1->MaxI = 200;
	ch1->MaxErr = 200;
	ch1->MaxOutput = 200;
	ch1->DeadBandGain = 0;
	ch1->DeadBandRange = 0;
	ch1->InputChan0 = 1;
	ch1->InputChan1 = 0;
	ch1->OutputChan0 = 13;
	ch1->OutputChan1 = 0;
	ch1->MasterAxis = -1;
	ch1->LimitSwitchOptions = 0x112;
	ch1->LimitSwitchNegBit = 1026;
	ch1->LimitSwitchPosBit = 1026;
	ch1->SoftLimitPos = 1e+09;
	ch1->SoftLimitNeg = -286500;
	ch1->InputGain0 = 1;
	ch1->InputGain1 = 1;
	ch1->InputOffset0 = 0;
	ch1->InputOffset1 = 0;
	ch1->OutputGain = 1;
	ch1->OutputOffset = 0;
	ch1->SlaveGain = 1;
	ch1->BacklashMode = BACKLASH_OFF;
	ch1->BacklashAmount = 0;
	ch1->BacklashRate = 0;
	ch1->invDistPerCycle = 1;
	ch1->Lead = 0;
	ch1->MaxFollowingError = 500;
	ch1->StepperAmplitude = 20;

	ch1->iir[0].B0 = 1;
	ch1->iir[0].B1 = 0;
	ch1->iir[0].B2 = 0;
	ch1->iir[0].A1 = 0;
	ch1->iir[0].A2 = 0;

	ch1->iir[1].B0 = 1;
	ch1->iir[1].B1 = 0;
	ch1->iir[1].B2 = 0;
	ch1->iir[1].A1 = 0;
	ch1->iir[1].A2 = 0;

	ch1->iir[2].B0 = 0.000768809;
	ch1->iir[2].B1 = 0.00153762;
	ch1->iir[2].B2 = 0.000768809;
	ch1->iir[2].A1 = 1.92081;
	ch1->iir[2].A2 = -0.923885;

	ch2->InputMode = ENCODER_MODE;
	ch2->OutputMode = CL_STEP_DIR_MODE;
	ch2->Vel = 270700;
	ch2->Accel = 7.7e+05;
	ch2->Jerk = 3.9e+06;
	ch2->P = 0;
	ch2->I = 0.003;
	ch2->D = 0;
	ch2->FFAccel = 0;
	ch2->FFVel = 0;
	ch2->MaxI = 400;
	ch2->MaxErr = 155;
	ch2->MaxOutput = 200;
	ch2->DeadBandGain = 0;
	ch2->DeadBandRange = 0;
	ch2->InputChan0 = 2;
	ch2->InputChan1 = 0;
	ch2->OutputChan0 = 14;
	ch2->OutputChan1 = 0;
	ch2->MasterAxis = -1;
	ch2->LimitSwitchOptions = 0x113;
	ch2->LimitSwitchNegBit = 1029;
	ch2->LimitSwitchPosBit = 1028;
	ch2->SoftLimitPos = 1e+09;
	ch2->SoftLimitNeg = -1e+09;
	ch2->InputGain0 = 1;
	ch2->InputGain1 = 1;
	ch2->InputOffset0 = 0;
	ch2->InputOffset1 = 0;
	ch2->OutputGain = 1;
	ch2->OutputOffset = 0;
	ch2->SlaveGain = 1;
	ch2->BacklashMode = BACKLASH_LINEAR;
	ch2->BacklashAmount = 5;
	ch2->BacklashRate = 90;
	ch2->invDistPerCycle = 1;
	ch2->Lead = 0;
	ch2->MaxFollowingError = 500;
	ch2->StepperAmplitude = 20;

	ch2->iir[0].B0 = 1.000000;
	ch2->iir[0].B1 = 0.000000;
	ch2->iir[0].B2 = 0.000000;
	ch2->iir[0].A1 = 0.000000;
	ch2->iir[0].A2 = 0.000000;

	ch2->iir[1].B0 = 1.000000;
	ch2->iir[1].B1 = 0.000000;
	ch2->iir[1].B2 = 0.000000;
	ch2->iir[1].A1 = 0.000000;
	ch2->iir[1].A2 = 0.000000;

	ch2->iir[2].B0 = 0.000769;
	ch2->iir[2].B1 = 0.001538;
	ch2->iir[2].B2 = 0.000769;
	ch2->iir[2].A1 = 1.920810;
	ch2->iir[2].A2 = -0.923885;







	EnableAxisDest(0, ch0->Position);
	//EnableAxisDest(0,ch0->Dest);
	EnableAxisDest(1, ch1->Position);
	//EnableAxisDest(1,ch1->Dest);
	EnableAxisDest(2, ch2->Position);
	//EnableAxisDest(2,ch2->Dest);

	FILE *f;
	double CTool = 0;

	f = fopen("c:\\KMotionFiles\\KFlopData.txt", "rt");
	if (!f)
	{
		printf("Unable to open file\n");
		return;
	}
	fscanf(f, "%lf", &CTool);
	fclose(f);
	persist.UserData[157] = CTool;
	printf("Current tool=%f\n", CTool);

	// Send MDI code to kmotion to display proper tool
	char s[80];
	sprintf(s, "T%d", persist.UserData[157]);
	MDI(s);						//send the T word


	SetBit(144);				//Enables Main Contactor Relay1 for servo drives with SWE kanalog output.
	// once the RESET button is clicked.
	SetBit(145);				//Enables Relay2 for enable/disable of servo drives and VFDwith SWE 
	// kanalog output. And controled by Estop switch.
	SetBit(159);				// WayLubePump          
	DefineCoordSystem(0, 1, 2, -1);	//DefineXYZ(A not used)



	{
		double Tau = 0.002;		//seconds for low pass filtertime constant
		KLP = exp(-TIMEBASE / Tau);
		printf("Tau=%f KLP=%f\n", Tau, KLP);
	}

	for (;;)					// loop forever




	{


		// convert quadrature to 2 bit binary
		BitA = ReadBit(QA);
		PosNoWrap = (ReadBit(QB) ^ BitA) | (BitA << 1);

		// Diff between expected position based on average of two prev deltas
		// and position with no wraps.  (Keep as X2 to avoid division by 2)

		DiffX2 = 2 * (Pos - PosNoWrap);	// + (Change2+Change1);

		// Calc quadrature wraparounds to bring Diff nearest zero
		// offset by 128 wraps to avoid requiring floor()
		wraps = ((DiffX2 + 1028) >> 3) - 128;

		// factor in the quadrature wraparounds
		NewPos = PosNoWrap + (wraps << 2);

		Change2 = Change1;
		Change1 = NewPos - Pos;
		Pos = NewPos;

		if (ReadBit(1048))		// is X1 selected?
			Factor = .5;
		else if (ReadBit(1046))	// is X10 selected?
			Factor = 5;
		else if (ReadBit(1045))	// is X100 selected?
			Factor = 50.;


		if (ReadBit(1052))		// is x selected?
			Axis = 0;
		else if (ReadBit(1055))	// is y selected?
			Axis = 1;
		else if (ReadBit(1053))	// is z selected?
			Axis = 2;
		else					// ignore encoder
			Change1 = 0;


		// check if the Axis just changed or we have been 
		// converging to the target for a long time
		if (Axis != LastAxis || (InMotion && Time_sec() > LastChangeTime + FINAL_TIME))
		{
			if (InMotion)
				Move(LastAxis, Target);	//finalize any motion

			LastAxis = Axis;
			InMotion = FALSE;
		}

		if (Change1)			// did we move?
		{
			if (!InMotion)
				Target = chan[Axis].Dest;
			Target += Change1 * Factor;
			MoveExp(Axis, Target, TAU);	// note: contains a WaitNextTimeSlice
			LastChangeTime = Time_sec();
			InMotion = TRUE;
		}
		else
		{

			WaitNextTimeSlice();	// execute loop once every time slice
			// check if all axes are enabled
			if (ch0->Enable && ch1->Enable && ch2->Enable)
			{
				SetBit(145);	// yes they are, enable the amplifier
			}
			else
			{
				ClearBit(145);	// no at least one is disabled, disable the amplifier
			}
			ServiceTimerSequence();	// service the timer sequencing
			UpdateJogSpeeds();


		}						// end of forever loop

	}
}

 //set Rate within Limits
void DoLimitJog(double rate, int cmd)
{
	if (rate < 0.0)
		rate = 0.0;
	if (rate > 1.0)
		rate = 1.0;

	DoPCFloat(cmd, rate);
}

void UpdateJogSpeeds(void)
{
	static LastChangeCount = -1;
	int Units, TWORD, HWORD, DWORD;
	double rate;

	// don't bother if nothing changed
	if (EditChangeCount == LastChangeCount)
		return;

	// remember count before updating
	LastChangeCount = EditChangeCount;

	// Read double from a KMotionCNC Edit Control
	// Persist Var identifies the Control and contents specifies 
	// where the string data should be placed in the 
	// Gather Buffer as an offset in words
	if (GetEditControlDouble(&rate, 170, 1000))
		return;					// exit if value is invalid

	GetMiscSettings(&Units, &TWORD, &HWORD, &DWORD);	// check Units
	if (Units == CANON_UNITS_MM)
		rate = rate / 25.4;		// convert screen value to ipm   
	DoLimitJog(rate / MAX_JOG_SPEED_X, PC_COMM_SET_JOG_OVERRIDE_X);
	DoLimitJog(rate / MAX_JOG_SPEED_Y, PC_COMM_SET_JOG_OVERRIDE_Y);
	DoLimitJog(rate / MAX_JOG_SPEED_Z, PC_COMM_SET_JOG_OVERRIDE_Z);


}


// sequence an IO Bit Based on Time in a non-blocking manner WAY LUBE PUMP

//#define TIME_ON 1800.0//seconds
//#define CYCLE_TIME 700.0 //seconds
//#define OUTPUT_BIT 159 // which IO bit to drive
void ServiceTimerSequence(void)
{
	//  static double T0=0.0;  // remember the last time we turned on
	//double T=Time_sec(); // get current Time_sec

	//if (T0==0.0 || T > T0 + CYCLE_TIME) T0=T;  // set start time of cycle

	//if (T < T0 + TIME_ON)  // are we within the TIME_ON section of the cycle?
	//  SetBit(OUTPUT_BIT);  //yes
	//else
	//  ClearBit(OUTPUT_BIT);  //no





	int result;



/// Handle FeedHold/Resume
//      result = Debounce(ReadBit(FEEDHOLDBIT),&fcount,&flast,&flastsolid);
	//  if  (result == 1)
	//{
	//if (CS0_StoppingState == 0)
	//StopCoordinatedMotion();
	//else
	//ResumeCoordinatedMotion();
	//}

	/// Handle Cycle Start
	//result = Debounce(ReadBit(CYCLESTARTBIT),&ccount,&clast,&clastsolid);
	//if  (result == 1)
	//{
	//DoPC(PC_COMM_EXECUTE);
	//}
	/// Handle Coolant Pump
	//result = Debounce(ReadBit(COOLANTBIT),&cocount,&colast,&colastsolid);
	//if  (result == 1)
	//{
	//if (ReadBit(154) == 1)
	//ClearBit(154);
	//else
	//SetBit(154);
	//}


	//}

	/// Handle ESTOP
	result = Debounce(ReadBit(ESTOP), &ecount, &elast, &elastsolid);
	if (result == 0)
	{
		DoPC(PC_COMM_ESTOP);
		ClearBit(145);			//Disable Servo Drives & vfd
		ClearBit(157);			//Turn off FloodCoolant
		ClearBit(158);			//Turn off Mist Coolant
		ClearBit(159);			//WayLubePump
		ClearBit(63);			//TC_OUT Solenoid
		ClearBit(62);			//TC_IN Solenoid
		ClearBit(61);			//TC_DOWN Solenoid
		ClearBit(60);			//TC_UP Solenoid
		ClearBit(59);			//Tool Release Solenoid
		ClearBit(48);			//ZeroServoCommand to VFD
		ClearBit(49);			//TC_CW
		ClearBit(50);			//TC_CCW
		ClearBit(156);			//SpindleOrientateProx minusVolt 
		SetBit(147);			// turn off spindle clockwise
		SetBit(148);			// turn off spindle counterclockwise
		MsgBox("E-STOP Condition", MB_OK | MB_ICONEXCLAMATION);
	}


	// Handle X Axis Servo Drives Error Line
	result = Debounce(ReadBit(XSDERRORLINEBIT), &xsdecount, &xsdelast, &xsdelastsolid);
	if (result == 1)
	{
		DoPC(PC_COMM_ESTOP);
		ClearBit(145);			//Disable Servo Drives & vfd
		SetBit(147);			// turn off spindle clockwise
		SetBit(148);			// turn off spindle counterclockwise
		ClearBit(157);			//Turn off FloodCoolant
		ClearBit(158);			//Turn off Mist Coolant

		MsgBox("X ServoDrive Fault", MB_OK | MB_ICONEXCLAMATION);
		ClearBit(144);			//Enable/Disable MainContactorRelay for servo drive main & logic power.
	}

	// Handle Y Axis Servo Drives Error Line
	result = Debounce(ReadBit(YSDERRORLINEBIT), &ysdecount, &ysdelast, &ysdelastsolid);
	if (result == 1)
	{
		DoPC(PC_COMM_ESTOP);
		ClearBit(145);			//Disable Servo Drives & vfd
		SetBit(147);			// turn off spindle clockwise
		SetBit(148);			// turn off spindle counterclockwise
		ClearBit(157);			//Turn off FloodCoolant
		ClearBit(158);			//Turn off Mist Coolant

		MsgBox("Y ServoDrive Fault", MB_OK | MB_ICONEXCLAMATION);
		ClearBit(144);			//Enable/Disable MainContactorRelay for servo drive main & logic power.
	}

	// Handle Z Axis Servo Drives Error Line
	result = Debounce(ReadBit(ZSDERRORLINEBIT), &zsdecount, &zsdelast, &zsdelastsolid);
	if (result == 1)
	{
		DoPC(PC_COMM_ESTOP);
		ClearBit(145);			//Disable Servo Drives & vfd
		SetBit(147);			// turn off spindle clockwise
		SetBit(148);			// turn off spindle counterclockwise
		ClearBit(157);			//Turn off FloodCoolant
		ClearBit(158);			//Turn off Mist Coolant

		MsgBox("Z ServoDrive Fault", MB_OK | MB_ICONEXCLAMATION);
		ClearBit(144);			//Enable/Disable MainContactorRelay for servo drive main & logic power.
	}
	// Handle VFD Error Output
	result = Debounce(ReadBit(VFDERRORLINEBIT), &vfdecount, &vfdelast, &vfdelastsolid);
	if (result == 1)
	{
		DoPC(PC_COMM_ESTOP);
		ClearBit(145);			//Disable Servo Drives & vfd
		SetBit(147);			// turn off spindle clockwise
		SetBit(148);			// turn off spindle counterclockwise
		ClearBit(157);			//Turn off FloodCoolant
		ClearBit(158);			//Turn off Mist Coolant

		MsgBox("VFD Fault", MB_OK | MB_ICONEXCLAMATION);
	}
	// Handle axis X minus limit switch
	result = Debounce(ReadBit(XMINUSLIMITBIT), &xmcount, &xmlast, &xmlastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("X - Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}
	// Handle axis X plus limit switch
	result = Debounce(ReadBit(XPLUSLIMITBIT), &xpcount, &xplast, &xplastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("X + Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}

	// Handle axis Y minus limit switch
	result = Debounce(ReadBit(YMINUSLIMITBIT), &ymcount, &ymlast, &ymlastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("Y - Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}
	// Handle axis Y plus limit switch
	result = Debounce(ReadBit(YPLUSLIMITBIT), &ypcount, &yplast, &yplastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("Y + Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}


	// Handle axis Z minus limit switch
	result = Debounce(ReadBit(ZMINUSLIMITBIT), &zmcount, &zmlast, &zmlastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("Z - Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}
	// Handle axis Z plus limit switch
	result = Debounce(ReadBit(ZPLUSLIMITBIT), &zpcount, &zplast, &zplastsolid);
	if (result == 1)
	{
		ClearBit(152);

		MsgBox("Z + Limit. Jog opposite direction.", MB_OK | MB_ICONEXCLAMATION);
	}
	// Handle HALT
	//result = Debounce(ReadBit(HALTBIT),&hcount,&hlast,&hlastsolid);
	//if  (result == 1)
	//{

}


		// Put a Float as a parameter and pass the command to the App
int DoPCFloat(int cmd, float f)
{
	int result;
	persist.UserData[PC_COMM_PERSIST + 1] = *(int *)&f;
	return DoPC(cmd);
}

		// Pass a command to the PC and wait for it to handshake
		// that it was received by either clearing the command
		// or changing it to a negative error code
int DoPC(int cmd)
{
	int result;

	persist.UserData[PC_COMM_PERSIST] = cmd;

	do
	{
		WaitNextTimeSlice();
	}
	while (result = persist.UserData[PC_COMM_PERSIST] > 0);

	printf("Result = %d\n", result);

	return result;
}

// Debounce a bit
//
// return 1 one time when first debounced high 
// return 0 one time when first debounced low 
// return -1 otherwise 
#define DBTIME 300

int Debounce(int n, int *cnt, int *last, int *lastsolid)
{
	int v = -1;

	if (n == *last)				// same as last time?
	{
		if (*cnt == DBTIME - 1)
		{
			if (n != *lastsolid)
			{
				v = *lastsolid = n;	// return debounced value
			}
		}
		if (*cnt < DBTIME)
			(*cnt)++;
	}
	else
	{
		*cnt = 0;				// reset count
	}
	*last = n;
	return v;


}

[TomKerekes]

Hi Troy,

Looks reasonable to me. Does the file exist in that directory? What prints on the Console?

[mmurray70]

Hi Mark,
I tried this before but has no effect leaving one opposite solenoid on. The air valve will stay maintained keeping air pressure on cylinder no matter what direction.

Do you know the make/model of your solenoid valve? It looks like you have 2 coils based on your program using 2 different bit numbers. Most valves with 2 coils are 3 position, with the center position just blocking all ports. This leaks down after a period of time and causes the problem I had with the amera seiki. It is possible that yours it a 2 position valve (extend/reverse only) toggled back and forth by 2 coils, but its not common. Usually there is just one coil and spring return for 2 position valves.

Originally i had all for open with mufflers. Then i plugged off 2 and that helped but still not soft like it should be.

This sounds odd. Kinda makes me wonder if something is connected wrong, replacing mufflers with plugs would normally be a major problem.

Have a read over this: https://www.omega.co.uk/auto/pdf/SimpValvesGuide.pdf

Another option that will work for you is to add flow control valves in the lines or right at the ports in the cylinder. Note that these valves only adjust flow in one direction, and the direction is important. Theres a bunch of info on these in that pdf too. Have a look at all your lines for flow control valves you may not have noticed. I still think your cylinder is most likely fine assuming its not leaking. They tend to last a very long time. Im always fearful of damaging something while fixing an item that wasn't even broke in the first place. Been there and done that lol.

Mark

[Need TECH Help!]

Hi Mark,
They are 2 position.
AutomationDirect
The manifold has 4 exhaust ports, 2 at each end, gives you the option to direct the exhaust. I have worked on Hardinge VMCs that use a similar manifold and they dont use any mufflers, just a long pc of hose.

I have control valves also but mettering it down to the point where it does not actuate as hard makes movement slow. A couple post back is a picture of the solenoid manifold assembly.

Troy

[Need TECH Help!]

Hi Troy,

Looks reasonable to me. Does the file exist in that directory? What prints on the Console?

It prints the statement from code "Unable to open file".
So i tried to delete file and windows said it was in use by KmotionServer. Then i opened file and typed 1.00000. And saved.
Now it prints after a tool change that current tool is T1. It doen not matter what tool i change to KmotionCNC active tool reverts back to T1. Unless i change the text file to another Tool number then that tool becomes active all the time.

Troy

[mmurray70]

Oh ok, you have brand new ones. I missed that picture sorry. I was thinking you were probably using the original solenoid valves and maybe had something mixed up. I see what you mean now about the exhaust ports/plugs in the manafold. All that looks good, Thats a nice neat setup.

If all else fails maybe you could try and slow it with your C-program. Instead of simply extending, I wonder if you could move most of the way, hit reverse for a split second to slow it, then continue the rest of way. Tune it with delays. Just a thought if nothing else works. Im surprised you cant find a good setup with the adjusters you have now.

[m_c]

Would the original valves not have one way restrictor/flow control valves, so the non-pressurised side return/vent flow is restricted, and acts as a buffer against the pressurised side?

[Need TECH Help!]

Hi m_C,
The other day i was looking at flow control valves and found one that has an exhaust built into it. Need to check if they are one way. Also noticed the gauge on my machine pressure regulator was reading about 85-90psi and shop pressure is 100-110. Did a quick test and lowered pressure regulator to about 60psi on gauge this helped more and i did not notice any speed reduction. Going to swap out the gauge today and see if its bad.

[TomKerekes]

Hi Troy,

It prints the statement from code "Unable to open file".
So i tried to delete file and windows said it was in use by KmotionServer. Then i opened file and typed 1.00000. And saved.
Now it prints after a tool change that current tool is T1. It doen not matter what tool i change to KmotionCNC active tool reverts back to T1. Unless i change the text file to another Tool number then that tool becomes active all the time.

If you load for example Tool #3 the following code:

// 13. Set Variables

	persist.UserData[157] = persist.UserData[6];	// Update current tool number
	persist.UserData[161] = 0;	// toolchanger finished

	printf("Tool changed to T%d\n", persist.UserData[157]);	// send message to console


// 14. Write current tool # disk


	FILE *f;

	float CTool = persist.UserData[157];	// s value from g code       

	f = fopen("c:\\KMotion Files\\KFlopData.txt", "wt");
	fprintf(f, "%f\n", CTool);
	fclose(f);

should print "Tool changed to 3" on the Console and if you look at the file KFlopData.txt it should contain 3.0000 and the time stamp in the file properties should be the time Tool 3 was loaded.

Does that occur?

[Need TECH Help!]

Hi Tom,
No the KFlopData.txt does not show the tool that was changed to.Will need to double check about the print out, but i believe it prints out what ever tool i typed into the KFlopData.txt file. Dont know about the time stamp, will check it also when i get home.
But,if i type 3.0000 into the KFlopData.txt file and save, then after i do a tool change in MDI line ,say M6T5. KMotionCNC will do the actual tool change to Tool5 and then KmotionCNC will show T3 as active.

Thanks,
Troy

[Need TECH Help!]

Hi Tom,
The time stamp is not changing on the text file unless i open it and save it. The print out is whatever i have entered in the text file and saved. I also have to re initialize my main INIT code in order for the print out tool number to reflect what i entered into the text file.

Also, i deleted the dot and zeros in the text file next to the tool number i entered and saved file. Then re-initialized main init code and did a tool change. Opened text file and now there is a dot and 6 zeros beside tool number in the text file.And the time stamp updates.

But,if i type 3.0000 into the KFlopData.txt file and save, then after i do a tool change in MDI line ,say M6T5. KMotionCNC will do the actual tool change to Tool5 and then KmotionCNC will show T3 as active.

This will only happen after i initialize my main INIT code.

Troy

[TomKerekes]

Hi Troy,

It seems the Tool Change M6 Program is not writing to the file for some reason. Does it print “Tool changed to X” when the M6 executes?