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

giantmolecules Mar 23, 2013 #

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

aldenStaff Mar 23, 2013 #

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

n7qvu Mar 23, 2013 #

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

aldenStaff Mar 23, 2013 #

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

giantmolecules Mar 23, 2013 #

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...

aldenStaff Mar 23, 2013 #

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

giantmolecules Mar 23, 2013 #

Thanks, Alden!

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

~BB~

giantmolecules Mar 24, 2013 #

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??

aldenStaff Mar 25, 2013 #

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

giantmolecules Mar 26, 2013 #

ok, alden, sent an email this morning...

thanks again!

~BB~

dj0nes Mar 17, 2014 #

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.

RileyStaff Mar 22, 2014 #

Dj0nes,

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

dj0nes Mar 22, 2014 #

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!

RileyStaff Mar 22, 2014 #

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

dj0nes Mar 22, 2014 #

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.

RileyStaff Mar 22, 2014 #

Ok this is weird indeed. My first thought would be to restore all config values to default. Lets see your config and see if I can replicate it.

ril3y