Problem Mach3 Partial Lockup


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Thread: Mach3 Partial Lockup

  1. #1
    Member vkonradi2's Avatar
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    Default Mach3 Partial Lockup

    I have a gantry configuration router with stepper motors and USB RnRMotionController, running purchased and licensed Mach3 on a Windows 7 Thinkpad. Laptop has all the power management and screen saver turned off, runs continuously.

    On several milling jobs recently I've experienced the Mach3 GUI stops updating the g-code display somewhere in the middle of the program. The CNC motion program actually completes successfully, except last line which stops the spindle fails to execute. I have to exit Mach3 to clean things up. Yesterday had a more severe variant of the failure where it corrupted my mill.xml file.

    So far when things screw up they don't seem to cause a motion error. I am thankful for that!

    The jobs are 3D milling, with pretty big files up to ~80,000 lines of g-code.

    Thoughts? Thanks!

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  2. #2
    Member vkonradi2's Avatar
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    Default Re: Mach3 Partial Lockup

    Confirming another instance of this. Machining sequence completes successfully. G-code display is stuck somewhere in the middle of the run. Spindle is still on, am able to turn it off manually. Unable to feed-hold and jog. Able to exit the program.

    Seems like an identifiable problem signature. Anyone seen this? Thanks!



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    Community Moderator ger21's Avatar
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    Default Re: Mach3 Partial Lockup

    Try turning off the toolpath display and see if it helps.

    Gerry

    UCCNC 2017 Screenset
    http://www.thecncwoodworker.com/2017.html

    Mach3 2010 Screenset
    http://www.thecncwoodworker.com/2010.html

    JointCAM - CNC Dovetails & Box Joints
    http://www.g-forcecnc.com/jointcam.html

    (Note: The opinions expressed in this post are my own and are not necessarily those of CNCzone and its management)


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    Member vkonradi2's Avatar
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    Default Re: Mach3 Partial Lockup

    Will try that. Had another instance today, and I can simply repeat the same cut with no work as a test. Does turning off the toolpath display mean editing the definition of the screen content? Or do you mean leaving the display there but disabling updates to it? The toolpath display shows up on two different tabs. Would I want to disable both? Thanks.



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    Default Re: Mach3 Partial Lockup

    Run-time option on Mach3 to turn the path display screen off. May help.
    How much free memory in the laptop?
    Any network connection (by any means)? This is a big no-no.

    At the worst, you could try re-installing Mach3.

    Cheers
    Roger



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    Member vkonradi2's Avatar
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    Default Re: Mach3 Partial Lockup

    Ger21 and Roger,

    Thanks for the suggestions. Turned off the path display and re-ran the program. Twice for good measure. First run terminated nominally. 2nd run terminated with all G code but the last completed per the code window display, and spindle still running. Stuck with a Mach3 error message which I could not close, could not touch Mach3 GUI, could not pull up program manager, had to hard boot the PC. It is XP, not Win7 as previously stated. Something is intermittent, not entirely deterministic (or I haven't identified the subtle determinism).

    No, not running any networking. Wireless is disabled and Ethernet is unplugged.

    How can the program motion commands all run to completion successfully, then get stuck with an error and fail to run just the last two lines in the file M05, M30??? That sounds like an identifiable signature!

    -Vadim



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    Default Re: Mach3 Partial Lockup

    Quote Originally Posted by vkonradi2 View Post
    Ger21 and Roger,

    Thanks for the suggestions. Turned off the path display and re-ran the program. Twice for good measure. First run terminated nominally. 2nd run terminated with all G code but the last completed per the code window display, and spindle still running. Stuck with a Mach3 error message which I could not close, could not touch Mach3 GUI, could not pull up program manager, had to hard boot the PC. It is XP, not Win7 as previously stated. Something is intermittent, not entirely deterministic (or I haven't identified the subtle determinism).

    No, not running any networking. Wireless is disabled and Ethernet is unplugged.

    How can the program motion commands all run to completion successfully, then get stuck with an error and fail to run just the last two lines in the file M05, M30??? That sounds like an identifiable signature!

    -Vadim
    Do you have a % at the top and bottom of the program this happens sometimes when this % code is missing

    Never use the pause button when cutting a program this is a known problem with Mach3

    May be it is time to get a UC100 that will free up your computer and run Mach3 a lot better, If you get one make sure it is genuine

    Mactec54


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    Default Re: Mach3 Partial Lockup

    Thinking...
    Not executing the m30 at the end could be one thing, although the program has run successfully on occasions.
    Not executing the m5 before that is another matter. That is a real problem.

    Question: when the program fails to terminate, is it always at the m5 line, or is it sometimes in other places? And is it always hung up so you can't do anything?

    Before spending any money, you could try reinstalling Mach3, using the .062 version rather than anything else. The version number is important.

    If that does not work then I suggest the problem must lie in the hardware. You could try replacing the RnR with a genuine UC100, or a genuine ESS from Warp9. Both are known to work well. Neither are expensive. Sadly, we do know some of the Chinese clones have faulty code in them and do not execute all g-codes properly.

    Cheers
    Roger



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    Member vkonradi2's Avatar
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    Default Re: Mach3 Partial Lockup

    When it gets stuck it seems right at the M5 line. The entire cut is completed successfully, and the spindle still spinning.

    The severity of hang is variable: (sometimes no failure), sometimes MACH3 GUI unresponsive but am able to x-out of the window, other times MACH3 showed a persistent error dialog and some kind of OS wedge so I have to hard boot the PC with the power button. When in that error dialog I click OK, and another different dialog flashes by too fast for me to see, then replaced by the same error dialog, endlessly. Maybe I could video the screen in slo-mo then play it back to see the other dialog.

    Interesting point about the Pause button. The total program is composed of 2 separate cuts, separated by a programmed pause and wait for cycle start. It self-pauses after making a boundary cut, I feed-hold, then jog far enough to remove the cut-off piece, then cycle-start to run the final cut 2nd sequence. But I am not doing any feed-hold while executing lines of code.

    I'll try adding the % lines. I'll check my MACH3 version tonight. Thanks!



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    Default Re: Mach3 Partial Lockup

    Quote Originally Posted by vkonradi2 View Post
    When it gets stuck it seems right at the M5 line. The entire cut is completed successfully, and the spindle still spinning.

    The severity of hang is variable: (sometimes no failure), sometimes MACH3 GUI unresponsive but am able to x-out of the window, other times MACH3 showed a persistent error dialog and some kind of OS wedge so I have to hard boot the PC with the power button. When in that error dialog I click OK, and another different dialog flashes by too fast for me to see, then replaced by the same error dialog, endlessly. Maybe I could video the screen in slo-mo then play it back to see the other dialog.

    Interesting point about the Pause button. The total program is composed of 2 separate cuts, separated by a programmed pause and wait for cycle start. It self-pauses after making a boundary cut, I feed-hold, then jog far enough to remove the cut-off piece, then cycle-start to run the final cut 2nd sequence. But I am not doing any feed-hold while executing lines of code.

    I'll try adding the % lines. I'll check my MACH3 version tonight. Thanks!
    Cut and past the last few lines of your program there may be something wrong with how it is formatted also

    Just add the % signs which should be in all programs it's part of how code should be formatted when there is a program fault it never stops at the actual fault line

    Because of what you are doing mid program I would make it 2 separate programs and the last move of your first cut I would have it move to where you want it, you never want to hit the feed hold and jog somewhere, this could end up being a disaster

    Mactec54


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    Default Re: Mach3 Partial Lockup

    Last few lines of the program are as follows. This was generated by DeskProto. This is the end of a waterline style 3D milling cut. A bunch of relative X-Y movements followed by a final absolute Z movement which raises the bit, then a command to turn off the spindle.
    G1 X323.571 Y-31.419
    G1 X323.286 Y-31.134
    G1 X323.000 Y-30.562
    G0 Z55.000
    M05
    M30

    I guessed my procedure to feed hold during a pause then jog for clearance was ok because the code following is an absolute movement. And because it works fine in practice. For me this construct is a practical way to generate my boundary cut and final cut together, maintain my organization. Agreed if the jog were followed by a relative movement it would in fact be a disaster. Is there a fault in that logic? Entirely possible I admit.

    In real-time programming the things that work sometimes and fail other times often boil down to timing. Maybe I need to insert a delay after the last move, before execution of the M05. For what root cause reason I have no idea. It just smells like it. I'm going to try that.

    Really appreciate the help!
    Vadim



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    Default Re: Mach3 Partial Lockup

    Quote Originally Posted by vkonradi2 View Post
    Last few lines of the program are as follows. This was generated by DeskProto. This is the end of a waterline style 3D milling cut. A bunch of relative X-Y movements followed by a final absolute Z movement which raises the bit, then a command to turn off the spindle.
    G1 X323.571 Y-31.419
    G1 X323.286 Y-31.134
    G1 X323.000 Y-30.562
    G0 Z55.000
    M05
    M30

    I guessed my procedure to feed hold during a pause then jog for clearance was ok because the code following is an absolute movement. And because it works fine in practice. For me this construct is a practical way to generate my boundary cut and final cut together, maintain my organization. Agreed if the jog were followed by a relative movement it would in fact be a disaster. Is there a fault in that logic? Entirely possible I admit.

    In real-time programming the things that work sometimes and fail other times often boil down to timing. Maybe I need to insert a delay after the last move, before execution of the M05. For what root cause reason I have no idea. It just smells like it. I'm going to try that.

    Really appreciate the help!
    Vadim
    The Feed hold is a known problem sometimes it works as you have found out, and sometimes it is a fail, your procedure may well be what the control likes when using the Feed Hold, and does it without any problems, my warning was just a heads up as I never had any problems with it as well, not that I used it very much

    Code is fine just needs the % top and bottom of the program, and it should all work as programed

    Mactec54


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    Default Re: Mach3 Partial Lockup

    Added the leading and trailing % lines. Each is %CRLF specifically. Ran the operation sequence 3 times and it failed on the 3rd run. Same symptom, all moves executed but the spindle-off command not executed and hung. So yeah it is one of those nasty intermittent things. Unfortunately did not respond to the % lines.

    I think I'll chop down the sequence, investigate if there is any dependence on length of the move sequence. If I can pare it down to a manageable size that executes quickly (and still fails) I can iterate on experiments without waiting hours of machine time. Maybe experiment with adding delays before the spindle-off command.



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    Default Re: Mach3 Partial Lockup

    Quote Originally Posted by vkonradi2 View Post
    Added the leading and trailing % lines. Each is %CRLF specifically. Ran the operation sequence 3 times and it failed on the 3rd run. Same symptom, all moves executed but the spindle-off command not executed and hung. So yeah it is one of those nasty intermittent things. Unfortunately did not respond to the % lines.

    I think I'll chop down the sequence, investigate if there is any dependence on length of the move sequence. If I can pare it down to a manageable size that executes quickly (and still fails) I can iterate on experiments without waiting hours of machine time. Maybe experiment with adding delays before the spindle-off command.
    How do you have the M5 On / Off controlled Relay or some other method, if you are having an electrical fault then it won't move past that point until it is completed

    Are you switching a VFD Drive On / Off

    A snip of your wiring would help could even be a Noise problem

    Mactec54


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