G code error


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    Default G code error

    Huge problem machining a 1" thick piece of aluminum 28" x 12" with
    Numerous 1/2" deep pockets. Using fusion adaptive program it's a 5 hour program to run, complex part. I'm doing it on diy router. 3 hp spindle cuts aluminum like butter. Ran program and about 3 hours into the program i get a g code error message click out of the error message another message box comes up i click out of that box and now I click the stop on the screen and have to start over.

    I already cut the perimeter of the piece so I redo the code using the part piece to set my zero referance. All going good and almost in the same spot after cutting air for 3 hours i get the same g code error just about in the spot.

    Adaptive code line N202165 G1 X0.3122 Y-9.1589 Z.3 next line is where arrow stopped in code is pointing in kmotion screen N202170 G3X0.3593 Y-9.1727 IO.0506 JO.085.

    Big problem what causes the g code error, and is there a way to start the program where it stopped so I don't have to cut air for 3 hours to get back to where it stopped? If you get a g code error is there a way to just start where you stopped without losing position and have to go back and re-zero.

    Joe

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    Gold Member TomKerekes's Avatar
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    Default Re: G code error

    Hi Joe,

    It looks like you have a letter 'O' instead of a zero '0' in your I J numbers.

    To start at a particular line of GCode right-mouse-click on the line of code and select "Set Next Statement". Note you must take care when doing this that it makes sense to do that instruction from where the tool currently is, that the proper tool is loaded, proper offset in use, etc. See here



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    Quote Originally Posted by TomKerekes View Post
    Hi Joe,

    It looks like you have a letter 'O' instead of a zero '0' in your I J numbers.

    To start at a particular line of GCode right-mouse-click on the line of code and select "Set Next Statement". Note you must take care when doing this that it makes sense to do that instruction from where the tool currently is, that the proper tool is loaded, proper offset in use, etc. See here
    Ran g code as simulation ran if a few seconds no error, I am able to switch off power to gecko drives and spindle and ran g code as if cutting material, ran for over five hours, completed g code with no errors.

    The g code failed twice when cutting material, I have had the happen 3 other times on other parts but re-ran the program and on the second run it worked.

    I have only used the machine to make about 25 parts. The machine is proving to be unreliable. What is causing the g code errors? Is it the computer glitching, the software unstable, the kflop board glitching, each time it gives a g code error stopping the program when I restart i loose my zero referance. Restarting with a newly established zero reference is not precisely as as the first, even .001 off causes ridges. Restarting the g code from the beginning and have another g code error is frustrating.

    What is the way to trouble shoot the g code error problem. The aluminum stock was expensive and machining with kmotion has proven unreliable. Again is it a computer issue, hard drive issue, software issue or kflop issue.

    I can't use the machine till the intermittent g code error issue is fixed.

    Joe



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    Gold Member TomKerekes's Avatar
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    Default Re: G code error

    Hi Joe,

    Sorry you are having difficulties. KFLOP and KMotionCNC are normally very reliable.

    I'm assuming you just copied the GCode into your last post incorrectly. But the code in the computer is ok?

    It would be helpful to know exactly what error you receive. Is it always at the same line?

    What type of system do you have? Open loop steppers?

    What Version of KMotion are you running? V4.34?



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    Default Re: G code error

    I am running version 4.33 on open loop stepper motors. I am in the process of making the parts for the gantry for my machine. The sides of the gantry pictured below were machined out of 1" aluminum. The other picture is the back plate for the z axis and is also 1" aluminum with 1/2" pockets machined in it. This was done on my machine using version 4.33 with open loop stepper motors. In machining the back plate, which is a 5 hour program to run, produces the g code error after about 3 hours and did it for a second time.

    I am thinking there is a glitch somewhere, should I try installing a new hard drive in the computer is it a computer problem, is kmotion or kflop the problem, the g code program is generated by fusion 360 and runs in simulated mode without error and with the stepper motor power supply off and the spindle off the g code I ran it without error but it is an intermittent problem. I have run 25 parts yet have at least have had 5 times of those 25 time that a g code error has stopped the program.

    I did not write down any error code, but when I get the g code error and click out of the error another message box appears that I click out of and I restart kmotion and initialize kflop to get kmotion back to working.

    To watch the machine run for 3 hours the have to start over watch it for another 3 hours and stop, has not gotten my part done as in the picture is sitting there half done.

    I nee advice on what to do

    Joe




    G code error-img_0609-jpgG code error-img_0610-jpg

    Attached Thumbnails Attached Thumbnails G code error-img_0609-jpg   G code error-img_0610-jpg  


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    Default Re: G code error

    Quote Originally Posted by mirocha View Post
    Ran g code as simulation ran if a few seconds no error, I am able to switch off power to gecko drives and spindle and ran g code as if cutting material, ran for over five hours, completed g code with no errors.

    The g code failed twice when cutting material, I have had the happen 3 other times on other parts but re-ran the program and on the second run it worked.

    I have only used the machine to make about 25 parts. The machine is proving to be unreliable. What is causing the g code errors? Is it the computer glitching, the software unstable, the kflop board glitching, each time it gives a g code error stopping the program when I restart i loose my zero referance. Restarting with a newly established zero reference is not precisely as as the first, even .001 off causes ridges. Restarting the g code from the beginning and have another g code error is frustrating.

    What is the way to trouble shoot the g code error problem. The aluminum stock was expensive and machining with kmotion has proven unreliable. Again is it a computer issue, hard drive issue, software issue or kflop issue.

    I can't use the machine till the intermittent g code error issue is fixed.

    Joe
    Those are nice looking parts to be made on a router! I have seen this a couple times when running from a USB drive. Run a program several times and its fine, then suddenly an error. But its very rare, like maybe once every couple months and i use my machine a fair bit. I just assumed it was an error with the USB drive, ive never seen it running from hard drive.



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    Default Re: G code error

    Hi Joe,

    I am running version 4.33 on open loop stepper motors. I am in the process of making the parts for the gantry for my machine.
    You might upgrade to V4,34 as well as use Windows Device Manager to update the Drivers to those in V4.34.

    I am thinking there is a glitch somewhere, should I try installing a new hard drive in the computer is it a computer problem, is kmotion or kflop the problem, the g code program is generated by fusion 360 and runs in simulated mode without error and with the stepper motor power supply off and the spindle off the g code I ran it without error but it is an intermittent problem. I have run 25 parts yet have at least have had 5 times of those 25 time that a g code error has stopped the program.
    Its hard to say, but I think it is unlikely to be any of those if it runs without errors with Motor and Spindle power off.

    Sounds possibly like a noise issue from the Spindle or Motor Drivers. Possibly causing Windows to disconnect the USB communication. Or do you have limit switches configured to disable axes that could be falsely triggered by noise?

    You might also try running tests with only Spindle Power or only Motor Drive Power to try to determine the noise source.

    Can you describe your system with regard to wiring, supplies, grounding, shielding? Is the USB cable short, with ferrite cores, and away from noise sources? Did you check the shield continuity to be less than 1 ohm? You might see this.

    I did not write down any error code
    Please be sure to write down exactly what error messages you receive. Also any other possible clues. Such as what the machine was doing, what was the state afterward, etc...



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    Quote Originally Posted by mmurray70 View Post
    Those are nice looking parts to be made on a router! I have seen this a couple times when running from a USB drive. Run a program several times and its fine, then suddenly an error. But its very rare, like maybe once every couple months and i use my machine a fair bit. I just assumed it was an error with the USB drive, ive never seen it running from hard drive.
    I copy my g code from my computer in my house to a usb thumb drive and use the usb thumb drive on the machine's dedicated computer to load the g code into kmotion. Am I understanding what you are saying is that the usb thumb drive may cause the problem. If so what's your recommendation to transfer the g code?



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    Default Re: G code error

    Quote Originally Posted by mirocha View Post
    I copy my g code from my computer in my house to a usb thumb drive and use the usb thumb drive on the machine's dedicated computer to load the g code into kmotion. Am I understanding what you are saying is that the usb thumb drive may cause the problem. If so what's your recommendation to transfer the g code?
    I normally do the same thing, I run off USB drive 99% of the time, but when I did get an error i just copied the file to the hard drive of the machines dedicated computer and it ran fine. Cant hurt to try anyway especially on a large file like that. I would think kmotioncnc can access the file quicker from the hard drive then from usb, Im not an expert with computers though, could be wrong.



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    Quote Originally Posted by TomKerekes View Post
    Hi Joe,

    You might upgrade to V4,34 as well as use Windows Device Manager to update the Drivers to those in V4.34.

    Its hard to say, but I think it is unlikely to be any of those if it runs without errors with Motor and Spindle power off.

    Sounds possibly like a noise issue from the Spindle or Motor Drivers. Possibly causing Windows to disconnect the USB communication. Or do you have limit switches configured to disable axes that could be falsely triggered by noise?

    You might also try running tests with only Spindle Power or only Motor Drive Power to try to determine the noise source.

    Can you describe your system with regard to wiring, supplies, grounding, shielding? Is the USB cable short, with ferrite cores, and away from noise sources? Did you check the shield continuity to be less than 1 ohm? You might see this.

    Please be sure to write down exactly what error messages you receive. Also any other possible clues. Such as what the machine was doing, what was the state afterward, etc...
    Ran program again, ran it from the USB and with tool in spindle cutting material to see what g code error message I was getting after 5 hours the program did not fail finished the part. Intermittent problems are the worst. Now all I can do is wait and see.



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    Default Re: G code error

    I finished the part that took over 5 hours without error. I went to reface the spoil board a simple back and forth cut. I ran the program and took off .003 with out problem 30" X 30" by .003 cut with out problem. Ran the same program to take off another .003 and the I received a G code error. I shut down the machine rebooted the computer and ran the program again and again I got a G code error. The error I got was "Kmotion DDL code error abort" when I closed that window another window popped up "Kmotion Auto Disconnect" and that's that.

    When the machine stopped the all axis stopped and the spindle remained running.

    The Kanalog is mounted using the ungrounded mounting holes.

    I have run this same program at least 30 time before without problem. Nothing has changed, the wiring has remained the same and the Kmotion version 4.33 on open loop stepper motors did not have problems before. The G Code error problem is getting more frequent. The only difference is the thumb drive is the same, 3.8 gig capacity and 1.77mb free its is about maxed out but I don't see that being a problem the program ran the first time and then failed twice the first time on line 90 of the program and the second time after rebooting it failed on line 10.

    Attached is the wiring diagram I am using, the limit switches are fed from a separate 24 volt power supply and optically separated, the usb cable is I believe the one supplied with the kanalog anyway it does have ferrite cores, the shields on the twisted pair limit switch cables are earth grounded not grounded to the kanalog ground but that has been that way all along.

    The spindle is fed with 4 conductor one is a ground wire earth grounded on both ends.

    I have not set up a 4th axis yet so that part of the drawing has not been connected yet, the wiring to the gecko server drive is in place but not connected.

    What do the error messages indicate, is it a kanalog error, computer error, it has run without issue and now the g code error is becoming more frequent making the system unusable.

    Should I consider putting in a new hard drive or a usb isolator. Can I send back the kanalog for you to test it to see if it fails for you under a controlled known noise free environment?

    I know you say KFLOP and KMotionCNC are normally very reliable, I like the program, I like your product and I hate to have to design and rewire for different controller but I'm at a lose I had no g code error issue and now it is getting more frequent and shorter run time before happening.

    Attached Files Attached Files


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    Default Re: G code error

    I would:
    - Run a full chkdsk on the thumb drive. Also run one on all drives on the computer that is running KmotionCNC.
    - delete unused files from the thumb drive, or ideally just try another one that is otherwise empty with just the file to reface the spoil board. See how that goes.
    - are you ejecting the thumb drive from the other computer before you bring it to the workshop computer? It's possible that the files are being corrupted.
    - how old is the thumb drive? Have you used it a lot? Perhaps it's at it's end of life.
    - It's not clear to me from your schematic but it looks like you have pin 16 of JP11 also tied to chassis ground? Or are you just showing that this is Kanalog ground? Shouldn't be tied to chassis ground.
    - The wire that you use for the analog +/-10vdc between Kanalog JP11 and your spindle VFD, is that shielded? Should be shielded and shield should only be connect at source end (Kanalog ground not chassis). Also this wire should not run parallel to any high voltage power cables, should cross them at 90 degrees. Do you have it in the same cable tray as the VFD power cable?
    - Is your VFD power cable (between VFD and motor) shielded? Should be quality VFD rated shielded cable, grounded at both ends.
    - have you changed any settings in the VFD recently? Like carrier frequency?
    - that it's becoming more frequent could suggest that it's a wiring issue. Perhaps one is being stressed from frequent motion. Are all your cables rated for machine use?
    - check all screw terminals for loose connections!
    - try to use a different computer to run KMotionCNC.

    FWIW I run a system with 3 VFD's all connected to Kanalog, with very long cable runs (65 feet to some limit switches and motors), and while my gcode programs are fairly short they do run for hours. Never seen this problem. I'm running 4.34j.

    Good luck.



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