motor 3 (Z) stalling on shapeoko when sending program file via coolterm

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  • March 22, 2013 at 9:58 pm #3922
    giantmolecules
    Member

    i’m flummoxed by this problem. have been trying for a couple of days to fix:

    i have a v7 tinyg board running firmware version 370.05 controlling a shapeoko machine under 24VDC. i communicate with it from my macbook pro running win7x64 on a bootcamp partition. i have absolutely no problem driving the machine around by sending individual lines of code, using single, double or triple-axis moves at rapid or programmed feedrates. but soon as i send a gcode file using coolterm (tried realterm, too), the 3rd motor, mapped to z, stalls (it makes some humming noises and has very low torque). i’ve tried this at various torque pot settings. i even decoupled the motor from the leadscrew, so i don’t think it’s the mechanics. software flow control is enabled both in firmware and in coolterm/realterm. i’ve checked the motor connections, and all seems fine. i am not getting any com errors in coolterm. i admit i haven’t tried moving the z axis to motor 4, but i’ve had enough for tonight. here’s my tinyg config dump. this is the umpteenth version, as i tried all manners of jerk settings, max velocity, feed maxes and microsteps. it all ends in the same result. is there anything glaringly wrong here? if not, any other ideas for a fix?

    $$

    [fb]  firmware build            370.05

    [fv]  firmware version            0.95

    [hv]  hardware version            7.00

    [id]  TinyG ID                    9H3583-PZQ

    [ja]  junction acceleration 1000000 mm

    [ct]  chordal tolerance           0.010 mm

    [st]  switch type                 0 [0=NO,1=NC]

    [ej]  enable json mode            0 [0=text,1=JSON]

    [jv]  json verbosity              4 [0=silent,1=footer,2=messages,3=configs,4=linenum,5=verbose]

    [tv]  text verbosity              1 [0=silent,1=verbose]

    [qv]  queue report verbosity      0 [0=off,1=filtered,2=verbose]

    [sv]  status report verbosity     0 [0=off,1=filtered,2=verbose]

    [si]  status interval            50 ms

    [ic]  ignore CR or LF on RX       0 [0=off,1=CR,2=LF]

    [ec]  expand LF to CRLF on TX     0 [0=off,1=on]

    [ee]  enable echo                 1 [0=off,1=on]

    [ex]  enable xon xoff             1 [0=off,1=on]

    [baud] USB baud rate              5 [1=9600,2=19200,3=38400,4=57600,5=115200,6=230400]

    [gpl] default gcode plane         0 [0=G17,1=G18,2=G19]

    [gun] default gcode units mode    1 [0=G20,1=G21]

    [gco] default gcode coord system  1 [1-6 (G54-G59)]

    [gpa] default gcode path control  2 [0=G61,1=G61.1,2=G64]

    [gdi] default gcode distance mode 0 [0=G90,1=G91]

    [1ma] m1 map to axis              0 [0=X,1=Y,2=Z…]

    [1sa] m1 step angle               1.800 deg

    [1tr] m1 travel per revolution   36.540 mm

    [1mi] m1 microsteps               4 [1,2,4,8]

    [1po] m1 polarity                 1 [0=normal,1=reverse]

    [1pm] m1 power management         1 [0=off,1=on]

    [2ma] m2 map to axis              1 [0=X,1=Y,2=Z…]

    [2sa] m2 step angle               1.800 deg

    [2tr] m2 travel per revolution   36.540 mm

    [2mi] m2 microsteps               4 [1,2,4,8]

    [2po] m2 polarity                 1 [0=normal,1=reverse]

    [2pm] m2 power management         1 [0=off,1=on]

    [3ma] m3 map to axis              2 [0=X,1=Y,2=Z…]

    [3sa] m3 step angle               1.800 deg

    [3tr] m3 travel per revolution    1.250 mm

    [3mi] m3 microsteps               4 [1,2,4,8]

    [3po] m3 polarity                 1 [0=normal,1=reverse]

    [3pm] m3 power management         1 [0=off,1=on]

    [4ma] m4 map to axis              3 [0=X,1=Y,2=Z…]

    [4sa] m4 step angle               1.800 deg

    [4tr] m4 travel per revolution  360.000 mm

    [4mi] m4 microsteps               8 [1,2,4,8]

    [4po] m4 polarity                 0 [0=normal,1=reverse]

    [4pm] m4 power management         1 [0=off,1=on]

    [xam] x axis mode                 1 [standard]

    [xvm] x velocity maximum      15000.000 mm/min

    [xfr] x feedrate maximum      10000.000 mm/min

    [xtm] x travel maximum          150.000 mm

    [xjm] x jerk maximum      500000000 mm/min^3

    [xjh] x jerk homing        20000000 mm/min^3

    [xjd] x junction deviation        1.0000 mm (larger is faster)

    [xsn] x switch min                1 [0=off,1=homing,2=limit,3=limit+homing]

    [xsx] x switch max                0 [0=off,1=homing,2=limit,3=limit+homing]

    [xsv] x search velocity         500.000 mm/min

    [xlv] x latch velocity          100.000 mm/min

    [xlb] x latch backoff             2.000 mm

    [xzb] x zero backoff              1.000 mm

    [yam] y axis mode                 1 [standard]

    [yvm] y velocity maximum      15000.000 mm/min

    [yfr] y feedrate maximum      10000.000 mm/min

    [ytm] y travel maximum          150.000 mm

    [yjm] y jerk maximum      500000000 mm/min^3

    [yjh] y jerk homing        20000000 mm/min^3

    [yjd] y junction deviation        1.0000 mm (larger is faster)

    [ysn] y switch min                1 [0=off,1=homing,2=limit,3=limit+homing]

    [ysx] y switch max                0 [0=off,1=homing,2=limit,3=limit+homing]

    [ysv] y search velocity         500.000 mm/min

    [ylv] y latch velocity          100.000 mm/min

    [ylb] y latch backoff             2.000 mm

    [yzb] y zero backoff              1.000 mm

    [zam] z axis mode                 1 [standard]

    [zvm] z velocity maximum       1000.000 mm/min

    [zfr] z feedrate maximum       1000.000 mm/min

    [ztm] z travel maximum           75.000 mm

    [zjm] z jerk maximum     1000000000 mm/min^3

    [zjh] z jerk homing        20000000 mm/min^3

    [zjd] z junction deviation        0.0500 mm (larger is faster)

    [zsn] z switch min                0 [0=off,1=homing,2=limit,3=limit+homing]

    [zsx] z switch max                1 [0=off,1=homing,2=limit,3=limit+homing]

    [zsv] z search velocity         400.000 mm/min

    [zlv] z latch velocity          100.000 mm/min

    [zlb] z latch backoff             2.000 mm

    [zzb] z zero backoff              1.000 mm

    [aam] a axis mode                 1 [standard]

    [avm] a velocity maximum       3600.000 deg/min

    [afr] a feedrate maximum       3600.000 deg/min

    [atm] a travel maximum           -1.000 deg

    [ajm] a jerk maximum       20000000 deg/min^3

    [ajh] a jerk homing        20000000 mm/min^3

    [ajd] a junction deviation        0.0500 deg (larger is faster)

    [ara] a radius value              1.0000 deg

    [asn] a switch min                1 [0=off,1=homing,2=limit,3=limit+homing]

    [asx] a switch max                0 [0=off,1=homing,2=limit,3=limit+homing]

    [asv] a search velocity         600.000 deg/min

    [alv] a latch velocity          100.000 deg/min

    [alb] a latch backoff             5.000 deg

    [azb] a zero backoff              2.000 deg

    [bam] b axis mode                 0 [disabled]

    [bvm] b velocity maximum       3600.000 deg/min

    [bfr] b feedrate maximum       3600.000 deg/min

    [btm] b travel maximum           -1.000 deg

    [bjm] b jerk maximum       20000000 deg/min^3

    [bjd] b junction deviation        0.0500 deg (larger is faster)

    [bra] b radius value              1.0000 deg

    [cam] c axis mode                 0 [disabled]

    [cvm] c velocity maximum       3600.000 deg/min

    [cfr] c feedrate maximum       3600.000 deg/min

    [ctm] c travel maximum           -1.000 deg

    [cjm] c jerk maximum       20000000 deg/min^3

    [cjd] c junction deviation        0.0500 deg (larger is faster)

    [cra] c radius value              1.0000 deg

    [p1frq] pwm frequency             0.000 Hz

    [p1csl] pwm cw speed lo           0.000 RPM

    [p1csh] pwm cw speed hi           0.000 RPM

    [p1cpl] pwm cw phase lo           0.000 [0..1]

    [p1cph] pwm cw phase hi           0.000 [0..1]

    [p1wsl] pwm ccw speed lo          0.000 RPM

    [p1wsh] pwm ccw speed hi          0.000 RPM

    [p1wpl] pwm ccw phase lo          0.000 [0..1]

    [p1wph] pwm ccw phase hi          0.000 [0..1]

    [p1pof] pwm phase off             0.000 [0..1]

    [g54x] g54 x offset               0.000 mm

    [g54y] g54 y offset               0.000 mm

    [g54z] g54 z offset               0.000 mm

    [g54a] g54 a offset               0.000 deg

    [g54b] g54 b offset               0.000 deg

    [g54c] g54 c offset               0.000 deg

    [g55x] g55 x offset              75.000 mm

    [g55y] g55 y offset              75.000 mm

    [g55z] g55 z offset               0.000 mm

    [g55a] g55 a offset               0.000 deg

    [g55b] g55 b offset               0.000 deg

    [g55c] g55 c offset               0.000 deg

    [g56x] g56 x offset               0.000 mm

    [g56y] g56 y offset               0.000 mm

    [g56z] g56 z offset               0.000 mm

    [g56a] g56 a offset               0.000 deg

    [g56b] g56 b offset               0.000 deg

    [g56c] g56 c offset               0.000 deg

    [g57x] g57 x offset               0.000 mm

    [g57y] g57 y offset               0.000 mm

    [g57z] g57 z offset               0.000 mm

    [g57a] g57 a offset               0.000 deg

    [g57b] g57 b offset               0.000 deg

    [g57c] g57 c offset               0.000 deg

    [g58x] g58 x offset               0.000 mm

    [g58y] g58 y offset               0.000 mm

    [g58z] g58 z offset               0.000 mm

    [g58a] g58 a offset               0.000 deg

    [g58b] g58 b offset               0.000 deg

    [g58c] g58 c offset               0.000 deg

    [g59x] g59 x offset               0.000 mm

    [g59y] g59 y offset               0.000 mm

    [g59z] g59 z offset               0.000 mm

    [g59a] g59 a offset               0.000 deg

    [g59b] g59 b offset               0.000 deg

    [g59c] g59 c offset               0.000 deg

    [g92x] g92 x offset               0.000 mm

    [g92y] g92 y offset               0.000 mm

    [g92z] g92 z offset               0.000 mm

    [g92a] g92 a offset               0.000 deg

    [g92b] g92 b offset               0.000 deg

    [g92c] g92 c offset               0.000 deg

    [g28x] g28 x location             0.000 mm

    [g28y] g28 y location             0.000 mm

    [g28z] g28 z location             0.000 mm

    [g28a] g28 a location             0.000 deg

    [g28b] g28 b location             0.000 deg

    [g28c] g28 c location             0.000 deg

    [g30x] g30 x location             0.000 mm

    [g30y] g30 y location             0.000 mm

    [g30z] g30 z location             0.000 mm

    [g30a] g30 a location             0.000 deg

    [g30b] g30 b location             0.000 deg

    [g30c] g30 c location             0.000 deg

    March 22, 2013 at 10:22 pm #3924
    alden
    Member

    Sorry you are having problems. Some questions:

    – Can you post the Gcode file you are running? What program generated the file?

    – When you say you are running flow control – I just want to confirm that you have Xon/Xoff enabled in coolterm

    – Does it fail in the same spot each time?

    – From your settings it looks like you have homing switches in place. Does the system make it through the homing cycle OK? G28.2 x0 y0 z0?

    Thx

    –Alden

    March 22, 2013 at 11:10 pm #3929
    n7qvu
    Member

    My 2 cents:

    It looks like your ZVM ([zvm] z velocity maximum 1000.000 mm/min) is very high.

    I could only get 500mm/min from mine before the motor would lock up. NEMA 17 steppers

    Have you tried a small move like G0 z1.0?
    Mine would freeze until I lowered ZVM.

    Jerry

    March 23, 2013 at 11:52 am #3935
    alden
    Member

    You might alos try dropping your Z jerk value and experimenting with motor 3 microsteps at 2 or even 1

    March 23, 2013 at 1:23 pm #3936
    giantmolecules
    Member

    Hey Folks,

    Thanks for your responses thus far…

    I recently updated to the new firmware master, and I’ve been tweaking the machine for no-load speeds for some special applications. My velocity, jerk and feedrates are higher than if I were using a tool to cut. I’ve verified these setting work reliably when entering single commands or sending simple programs via CoolTerm.

    I do have XON enabled:

    http://brettbalogh.tumblr.com/post/46083783802

     

    If I send a simple program like this:

    G21

    G90

    G0Z75.00

    Z0.00

    G1Z75.00F1000

    Z0.00

    M30

     

    This is the result:

    http://brettbalogh.tumblr.com/post/46081363353

     

    But if I send something more complicated:

    G0G90G21

    (Engraving)

    G00 Z90.00

    X93.59 Y46.90

    G01 Z87.00  F250

    X91.38 Y52.79  F10000

    X91.17 Y61.86

    X92.98 Y70.92

    X96.70 Y77.24

    X104.50 Y84.74

    X105.26 Y89.49

    X103.49 Y95.62

    X94.51 Y117.56

    X92.37 Y134.02

    X93.82 Y148.42

    X97.44 Y148.46

    X101.94 Y144.08

    X105.76 Y137.14

    X107.54 Y129.36

    X105.66 Y97.30

    X107.50 Y65.16

    X105.78 Y57.44

    X102.07 Y50.67

    X97.54 Y46.53

    X93.59 Y46.90

    X93.76 Z84.00

    X93.73 Y46.28

    X92.23 Y47.88

    X92.47 Y51.33

    X92.76 Y64.06

    X92.88 Y76.45

    X92.66 Y82.87

    X92.65 Y85.99

    X95.31 Y86.43

    Y86.57

    X94.84 Y99.61

    X97.91 Y103.12

    X102.28 Y103.61

    X99.13 Y102.63

    X94.83 Y104.26

    X93.01 Y108.52

    X93.76 Y148.00

    G00 Z90.00

    X95.45 Y149.35

    G01 Z78.00  F250

    X95.70 Y148.00  F10000

    X95.45 Y149.35

    G00 Z90.00

    X97.28 Y148.00

    G01 Z78.00  F250

    X97.51 Y149.40  F10000

    X99.09 Y149.34

    X102.22 Y149.35

    X102.00 Y147.95

    X100.41 Y148.01

    X97.28 Y148.00

    G00 Z90.00

    X94.72 Y147.74

    G01 Z75.00  F250

    X100.69 Y147.77  F10000

    X103.77 Y147.59

    X105.18 Y149.28

    X99.21 Y149.25

    X96.12 Y149.43

    X94.72 Y147.74

    G00 Z90.00

    X92.00 Y148.82

    G01 Z72.00  F250

    X90.85 Y140.79  F10000

    X92.14 Y131.28

    X91.70 Y113.94

    X92.10 Y96.71

    X94.61 Y93.94

    X98.98 Y92.66

    X107.63 Y94.96

    X109.16 Y103.11

    X108.12 Y112.84

    X108.36 Y130.22

    X107.52 Y147.97

    X104.93 Y150.66

    X100.53 Y151.66

    X92.00 Y148.82

    G00 Z90.00

    X91.52 Y137.98

    G01 Z66.00  F250

    M30

     

    This is what I get:

    http://brettbalogh.tumblr.com/post/46082951794

     

    You can hear the buzzing when the z-axis stalls.

    I guess the big question is this: Why do I not have problems with the first program, but I do with the second?

    By the way, the code was generated with RhinoV4+RhinoCAM using a post customized for the ShapeOko.

    Thanks again…

    March 23, 2013 at 3:24 pm #3937
    alden
    Member

    Your Z jerk might be too high. You have it set to 1,000,000,000.  (1billion) I set my shapeoko Z to 50million. I’d try to get Z working with the following settings:

    Run G21 first so all settings are in mm mode
$3mi=2          set motor3 to 2 microsteps (assuming motor 3 is mapped to the Z axis
$zvm=400        set max velocity to 400 mm/min. Shapeoko Z should be able to do 1000, but don't start there  
$zjm=10000000   10 million. Ramp up to about 50 million once you clear the lower numbers

    Then ramp up slowly to $zvm=1000 and $zjm=50000000 (50 million)

    I’m writing instructions on the wiki as we’ve seen this type of problem before – it’s usually a settings problem. Even if it’s not your issue the instructions might help.  It also has some other things you might check if this doesn’t work.

    https://github.com/synthetos/TinyG/wiki/Troubleshooting#z-axis-stalls-during-gcode-file

     

    March 23, 2013 at 6:45 pm #3938
    giantmolecules
    Member

    Thanks, Alden!

    I tried your settings, but the problem persists. I even loosened the coupler to the leadscrew and it still happens.

     

    ~BB~

    March 23, 2013 at 10:21 pm #3939
    giantmolecules
    Member

    i switched the z-axis to motor 4 on the tinyg board and configured it as i had motor 3 before. no problems. runs like a champ now. i now guess it’s something electrical with the tinyg board rather than software/mechanical??

    March 24, 2013 at 9:01 pm #3944
    alden
    Member

    SOunds like it. Let’s get a return going. Please contact us at the synthetos gmail address.

    March 26, 2013 at 12:29 am #3953
    giantmolecules
    Member

    ok, alden, sent an email this morning…

    thanks again!

    ~BB~

    March 17, 2014 at 3:39 pm #5643
    dj0nes
    Member

    Hi! Did the return solve the z axis binding issue? I am having the same problem on my Shapeoko machine and have followed the steps outlined in this thread.

    March 22, 2014 at 3:49 pm #5655
    Riley
    Keymaster

    Dj0nes,

    What is your zaxis issues? I want to be clear we are dealing with the same thing?

    March 22, 2014 at 4:13 pm #5656
    dj0nes
    Member

    Hey Riley,

    My situation is very similar to the OP’s. I am using a v8 TinyG to control a v1 Shapeoko machine. When sending gcode files via Coolterm, the Z-axis will go down without an issue, but will not go back up – it just makes a buzzing noise.

    The gcode in question is part of a larger file, but the issue is apparent with just the following:

    G00 Z 3.0000
G00 X 121.5942 Y 92.8307

G01 Z -0.1250 F 100.0000(Penetrate)
G02 X 121.4341 Y 92.2331 Z -0.1250 I -1.1952 J -0.0000 F 400.0000
G02 X 120.9966 Y 91.7956 Z -0.1250 I -1.0351 J 0.5976
G02 X 121.5942 Y 92.8307 Z -0.1250 I -1.0351 J -0.5976
G01 X 121.5942 Y 92.8307 Z -0.1250
G00 Z 3.0000

G01 Z -0.1250 F 100.0000(Penetrate)
G02 X 121.4341 Y 92.2331 Z -0.1250 I -1.1952 J -0.0000 F 400.0000
G02 X 120.9966 Y 91.7956 Z -0.1250 I -1.0351 J 0.5976
G02 X 121.5942 Y 92.8307 Z -0.1250 I -1.0351 J -0.5976
G01 X 121.5942 Y 92.8307 Z -0.1250
G00 Z 3.0000

G01 Z -0.1250 F 100.0000(Penetrate)
G02 X 121.4341 Y 92.2331 Z -0.1250 I -1.1952 J -0.0000 F 400.0000
G02 X 120.9966 Y 91.7956 Z -0.1250 I -1.0351 J 0.5976
G02 X 121.5942 Y 92.8307 Z -0.1250 I -1.0351 J -0.5976
G01 X 121.5942 Y 92.8307 Z -0.1250
G00 Z 3.0000

    I have tried lowering the jerk, max z velocity, and microstepping with no change in performance. I have also tried swapping the z motor’s connection from motor 1 to 3, also with no difference.

    The z axis performs without issue when typing in commands one at a time and hitting enter, so this doesn’t seem to be an issue with motor current or the machine itself. Flow control is on.

    Any ideas?

    Cheers!

    March 22, 2014 at 4:38 pm #5657
    Riley
    Keymaster

    So NONE of the G00 Z 3.0000’s go back up while sending files?

    However if do a G0 Z 3.0000 at the command line it works?

    ril3y

    March 22, 2014 at 4:45 pm #5658
    dj0nes
    Member

    Correct – just a buzzing noise when it the axis should go back up while sending a file.

    Entering the command in manually works, even immediately after sending the file.

    I am traveling until Wednesday, but could provide you with a video and full config info when I get back.

    • This reply was modified 10 years, 9 months ago by dj0nes.
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