Dynomotion

Group: DynoMotion Message: 1495 From: morgtod Date: 7/13/2011
Subject: Unexpected overflow
I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!


Todd
Group: DynoMotion Message: 1496 From: Tom Kerekes Date: 7/13/2011
Subject: Re: Unexpected overflow
Hi Todd,
 
Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
 
I assume you are running KMotionCNC?  What Version?
 
I assume you have Servos?
 
Was it working before?
 
What is your Following Error Limit set at?
 
Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
 
Thanks
TK
 


--- On Wed, 7/13/11, morgtod <todmorg@...> wrote:

From: morgtod <todmorg@...>
Subject: [DynoMotion] Unexpected overflow
To: DynoMotion@yahoogroups.com
Date: Wednesday, July 13, 2011, 5:41 PM

 
I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!

Todd

Group: DynoMotion Message: 1497 From: morgtod Date: 7/13/2011
Subject: Re: Unexpected overflow
KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
It stops at the same spot, if I'm cutting metal or air.
I'm not sure if this is a new problem, these are some of the first large files I'm running.
On one of the G-code files, it stops on gradual contour arc ( always the same spot )
On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.


The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.

Todd


--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
>  
> I assume you are running KMotionCNC?  What Version?
>  
> I assume you have Servos?
>  
> Was it working before?
>  
> What is your Following Error Limit set at?
>  
> Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
>  
> Thanks
> TK
>  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 5:41 PM
>
>
>  
>
>
>
> I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
>
> Todd
>
Group: DynoMotion Message: 1498 From: morgtod Date: 7/13/2011
Subject: Re: Unexpected overflow
Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.

--- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@...> wrote:
>
> KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> It stops at the same spot, if I'm cutting metal or air.
> I'm not sure if this is a new problem, these are some of the first large files I'm running.
> On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
>
>
> The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
>
> Todd
>
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> >  
> > I assume you are running KMotionCNC?  What Version?
> >  
> > I assume you have Servos?
> >  
> > Was it working before?
> >  
> > What is your Following Error Limit set at?
> >  
> > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> >  
> > Thanks
> > TK
> >  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 5:41 PM
> >
> >
> >  
> >
> >
> >
> > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> >
> > Todd
> >
>
Group: DynoMotion Message: 1499 From: Tom Kerekes Date: 7/13/2011
Subject: Re: Unexpected overflow
Hi Todd,
 
There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
 
If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
 
Thanks
TK
 
 


--- On Wed, 7/13/11, morgtod <todmorg@...> wrote:

From: morgtod <todmorg@...>
Subject: [DynoMotion] Re: Unexpected overflow
To: DynoMotion@yahoogroups.com
Date: Wednesday, July 13, 2011, 6:07 PM

 
Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.

--- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@...> wrote:
>
> KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> It stops at the same spot, if I'm cutting metal or air.
> I'm not sure if this is a new problem, these are some of the first large files I'm running.
> On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
>
>
> The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
>
> Todd
>
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> >  
> > I assume you are running KMotionCNC?  What Version?
> >  
> > I assume you have Servos?
> >  
> > Was it working before?
> >  
> > What is your Following Error Limit set at?
> >  
> > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> >  
> > Thanks
> > TK
> >  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 5:41 PM
> >
> >
> >  
> >
> >
> >
> > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> >
> > Todd
> >
>
Group: DynoMotion Message: 1500 From: morgtod Date: 7/13/2011
Subject: Re: Unexpected overflow
I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???


Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!


--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
>  
> If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
>  
> Thanks
> TK
>  
>  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 6:07 PM
>
>
>  
>
>
>
> Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
>
> --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> >
> > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > It stops at the same spot, if I'm cutting metal or air.
> > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> >
> >
> > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> >
> > Todd
> >
> >
> > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > >
> > > Hi Todd,
> > >  
> > > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > >  
> > > I assume you are running KMotionCNC?  What Version?
> > >  
> > > I assume you have Servos?
> > >  
> > > Was it working before?
> > >  
> > > What is your Following Error Limit set at?
> > >  
> > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > >  
> > > Thanks
> > > TK
> > >  
> > >
> > >
> > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > >
> > >
> > > From: morgtod <todmorg@>
> > > Subject: [DynoMotion] Unexpected overflow
> > > To: DynoMotion@yahoogroups.com
> > > Date: Wednesday, July 13, 2011, 5:41 PM
> > >
> > >
> > >  
> > >
> > >
> > >
> > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > >
> > > Todd
> > >
> >
>
Group: DynoMotion Message: 1501 From: Tom Kerekes Date: 7/13/2011
Subject: Re: Unexpected overflow
Hi Todd,
 
The patch was described here:
 
 
 
USB disconnects might be caused by a grounding issue.  Possibly earth ground between the machine and the PC.  Do you have any clues about what causes it?  For example does it ever happen with the Spindle off?  Unfortunately if the USB disconnects there is no way to send a Reboot! command.  Check in Windows | Control Panel | Device Manager to see if the KFLOP device is still present.  If you just unplug the USB and Re-connect it without cycling power on KFLOP does the system still function?
 
Thanks
TK  


--- On Wed, 7/13/11, morgtod <todmorg@...> wrote:

From: morgtod <todmorg@...>
Subject: [DynoMotion] Re: Unexpected overflow
To: DynoMotion@yahoogroups.com
Date: Wednesday, July 13, 2011, 7:22 PM

 
I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???

Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!

--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
>  
> If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
>  
> Thanks
> TK
>  
>  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 6:07 PM
>
>
>  
>
>
>
> Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
>
> --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> >
> > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > It stops at the same spot, if I'm cutting metal or air.
> > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> >
> >
> > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> >
> > Todd
> >
> >
> > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > >
> > > Hi Todd,
> > >  
> > > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > >  
> > > I assume you are running KMotionCNC?  What Version?
> > >  
> > > I assume you have Servos?
> > >  
> > > Was it working before?
> > >  
> > > What is your Following Error Limit set at?
> > >  
> > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > >  
> > > Thanks
> > > TK
> > >  
> > >
> > >
> > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > >
> > >
> > > From: morgtod <todmorg@>
> > > Subject: [DynoMotion] Unexpected overflow
> > > To: DynoMotion@yahoogroups.com
> > > Date: Wednesday, July 13, 2011, 5:41 PM
> > >
> > >
> > >  
> > >
> > >
> > >
> > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > >
> > > Todd
> > >
> >
>
Group: DynoMotion Message: 1502 From: morgtod Date: 7/14/2011
Subject: Re: Unexpected overflow
Removing the corner tolerance made a huge differance in the way the machine runs, I was getting real hard clunks when the feed rate was changed during a cut, but these smoothe out now. I will do the patch when I get a chance.
The usb dropout is almost always when switching a solenoid or motor off, I've been very careful about central point grounding on everything. The 120 volt side is powered by a 240/120 transformer, the 120 neutral is bonded to ground, the servos are powered by a 240/50ish volt transformer the negative is bonded to ground after the diodes and caps( not sure if this is necesary or correct ). The low voltage comes from a 120 to 24,+15,-15,12 and 5 volt power supply, all the negatives are tied together and bonded to ground. There is a direct ground from the electric panel to the electrical cabinet. All VFD's and motors are chassis grounded. Am I missing something important or doing something incorrect?

Todd



--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> The patch was described here:
>  
> http://tech.groups.yahoo.com/group/DynoMotion/message/1265
>  
>  
> USB disconnects might be caused by a grounding issue.  Possibly earth ground between the machine and the PC.  Do you have any clues about what causes it?  For example does it ever happen with the Spindle off?  Unfortunately if the USB disconnects there is no way to send a Reboot! command.  Check in Windows | Control Panel | Device Manager to see if the KFLOP device is still present.  If you just unplug the USB and Re-connect it without cycling power on KFLOP does the system still function?
>  
> Thanks
> TK  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 7:22 PM
>
>
>  
>
>
>
> I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???
>
> Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
> >  
> > If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
> >  
> > Thanks
> > TK
> >  
> >  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Re: Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 6:07 PM
> >
> >
> >  
> >
> >
> >
> > Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
> >
> > --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> > >
> > > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > > It stops at the same spot, if I'm cutting metal or air.
> > > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> > >
> > >
> > > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> > >
> > > Todd
> > >
> > >
> > > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > > >
> > > > Hi Todd,
> > > >  
> > > > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > > >  
> > > > I assume you are running KMotionCNC?  What Version?
> > > >  
> > > > I assume you have Servos?
> > > >  
> > > > Was it working before?
> > > >  
> > > > What is your Following Error Limit set at?
> > > >  
> > > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > > >  
> > > > Thanks
> > > > TK
> > > >  
> > > >
> > > >
> > > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > > >
> > > >
> > > > From: morgtod <todmorg@>
> > > > Subject: [DynoMotion] Unexpected overflow
> > > > To: DynoMotion@yahoogroups.com
> > > > Date: Wednesday, July 13, 2011, 5:41 PM
> > > >
> > > >
> > > >  
> > > >
> > > >
> > > >
> > > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > > >
> > > > Todd
> > > >
> > >
> >
>
Group: DynoMotion Message: 1505 From: morgtod Date: 7/15/2011
Subject: Re: Unexpected overflow
Tom,
I just noticed your note about the ground between the PC and the machine. I'm using a Panasonic toughbook laptop mounted in a removable cradle. The cradle is mounted to the machine chassis, so the cradle is grounded, but I don't know if this provides an earth ground to the laptop. I'm not even sure where you would connect to the laptop to provide ground

Todd

--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> The patch was described here:
>  
> http://tech.groups.yahoo.com/group/DynoMotion/message/1265
>  
>  
> USB disconnects might be caused by a grounding issue.  Possibly earth ground between the machine and the PC.  Do you have any clues about what causes it?  For example does it ever happen with the Spindle off?  Unfortunately if the USB disconnects there is no way to send a Reboot! command.  Check in Windows | Control Panel | Device Manager to see if the KFLOP device is still present.  If you just unplug the USB and Re-connect it without cycling power on KFLOP does the system still function?
>  
> Thanks
> TK  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 7:22 PM
>
>
>  
>
>
>
> I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???
>
> Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
> >  
> > If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
> >  
> > Thanks
> > TK
> >  
> >  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Re: Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 6:07 PM
> >
> >
> >  
> >
> >
> >
> > Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
> >
> > --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> > >
> > > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > > It stops at the same spot, if I'm cutting metal or air.
> > > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> > >
> > >
> > > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> > >
> > > Todd
> > >
> > >
> > > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > > >
> > > > Hi Todd,
> > > >  
> > > > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > > >  
> > > > I assume you are running KMotionCNC?  What Version?
> > > >  
> > > > I assume you have Servos?
> > > >  
> > > > Was it working before?
> > > >  
> > > > What is your Following Error Limit set at?
> > > >  
> > > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > > >  
> > > > Thanks
> > > > TK
> > > >  
> > > >
> > > >
> > > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > > >
> > > >
> > > > From: morgtod <todmorg@>
> > > > Subject: [DynoMotion] Unexpected overflow
> > > > To: DynoMotion@yahoogroups.com
> > > > Date: Wednesday, July 13, 2011, 5:41 PM
> > > >
> > > >
> > > >  
> > > >
> > > >
> > > >
> > > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > > >
> > > > Todd
> > > >
> > >
> >
>
Group: DynoMotion Message: 1506 From: Tom Kerekes Date: 7/15/2011
Subject: Re: Unexpected overflow
Hi Todd,
 
Yes grounding is very complex.  I could think of advantages and disadvantages of earth-grounding the PC.  And also how - grounding to the machine frame probably isn't a good idea.  To check if it is earth grounded use an ohm meter between the USB shield connector on the PC and earth ground while everything is disconnected from the PC.
 
I can't really follow your description of the topology of your grounding in your previous email, but it sounds like you might have some ground loops.  Maybe try disconnecting the connection from the +5 DC supply's DC ground to earth ground.  And/or the 50VDC's ground to earth ground.  This will basically leave them floating but there will still probably be another earth ground path.
 
Regards
TK

--- On Fri, 7/15/11, morgtod <todmorg@...> wrote:

From: morgtod <todmorg@...>
Subject: [DynoMotion] Re: Unexpected overflow
To: DynoMotion@yahoogroups.com
Date: Friday, July 15, 2011, 7:17 AM

 
Tom,
I just noticed your note about the ground between the PC and the machine. I'm using a Panasonic toughbook laptop mounted in a removable cradle. The cradle is mounted to the machine chassis, so the cradle is grounded, but I don't know if this provides an earth ground to the laptop. I'm not even sure where you would connect to the laptop to provide ground

Todd

--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> The patch was described here:
>  
> http://tech.groups.yahoo.com/group/DynoMotion/message/1265
>  
>  
> USB disconnects might be caused by a grounding issue.  Possibly earth ground between the machine and the PC.  Do you have any clues about what causes it?  For example does it ever happen with the Spindle off?  Unfortunately if the USB disconnects there is no way to send a Reboot! command.  Check in Windows | Control Panel | Device Manager to see if the KFLOP device is still present.  If you just unplug the USB and Re-connect it without cycling power on KFLOP does the system still function?
>  
> Thanks
> TK  
>
>
> --- On Wed, 7/13/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Wednesday, July 13, 2011, 7:22 PM
>
>
>  
>
>
>
> I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???
>
> Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
> >  
> > If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
> >  
> > Thanks
> > TK
> >  
> >  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Re: Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 6:07 PM
> >
> >
> >  
> >
> >
> >
> > Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
> >
> > --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> > >
> > > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > > It stops at the same spot, if I'm cutting metal or air.
> > > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> > >
> > >
> > > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> > >
> > > Todd
> > >
> > >
> > > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > > >
> > > > Hi Todd,
> > > >  
> > > > Apparently you are getting a Following Error Axis 0.  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > > >  
> > > > I assume you are running KMotionCNC?  What Version?
> > > >  
> > > > I assume you have Servos?
> > > >  
> > > > Was it working before?
> > > >  
> > > > What is your Following Error Limit set at?
> > > >  
> > > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > > >  
> > > > Thanks
> > > > TK
> > > >  
> > > >
> > > >
> > > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > > >
> > > >
> > > > From: morgtod <todmorg@>
> > > > Subject: [DynoMotion] Unexpected overflow
> > > > To: DynoMotion@yahoogroups.com
> > > > Date: Wednesday, July 13, 2011, 5:41 PM
> > > >
> > > >
> > > >  
> > > >
> > > >
> > > >
> > > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > > >
> > > > Todd
> > > >
> > >
> >
>
Group: DynoMotion Message: 1507 From: morgtod Date: 7/15/2011
Subject: Re: Unexpected overflow
Tom,

The bonding on the 2 dc power supplies was there from the factory, I assumed it was correct, you kow what happens when you assume,( ass/u/me ). I removed both ground bonds and the usb disconnects seem to have stopped.

Thanks again!!!
Todd

--- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@...> wrote:
>
> Hi Todd,
>  
> Yes grounding is very complex.  I could think of advantages and disadvantages of earth-grounding the PC.  And also how - grounding to the machine frame probably isn't a good idea.  To check if it is earth grounded use an ohm meter between the USB shield connector on the PC and earth ground while everything is disconnected from the PC.
>  
> I can't really follow your description of the topology of your grounding in your previous email, but it sounds like you might have some ground loops.  Maybe try disconnecting the connection from the +5 DC supply's DC ground to earth ground.  And/or the 50VDC's ground to earth ground.  This will basically leave them floating but there will still probably be another earth ground path.
>  
> Regards
> TK
>
> --- On Fri, 7/15/11, morgtod <todmorg@...> wrote:
>
>
> From: morgtod <todmorg@...>
> Subject: [DynoMotion] Re: Unexpected overflow
> To: DynoMotion@yahoogroups.com
> Date: Friday, July 15, 2011, 7:17 AM
>
>
>  
>
>
>
> Tom,
> I just noticed your note about the ground between the PC and the machine. I'm using a Panasonic toughbook laptop mounted in a removable cradle. The cradle is mounted to the machine chassis, so the cradle is grounded, but I don't know if this provides an earth ground to the laptop. I'm not even sure where you would connect to the laptop to provide ground
>
> Todd
>
> --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> >
> > Hi Todd,
> >  
> > The patch was described here:
> >  
> > http://tech.groups.yahoo.com/group/DynoMotion/message/1265
> >  
> >  
> > USB disconnects might be caused by a grounding issue.  Possibly earth ground between the machine and the PC.  Do you have any clues about what causes it?  For example does it ever happen with the Spindle off?  Unfortunately if the USB disconnects there is no way to send a Reboot! command.  Check in Windows | Control Panel | Device Manager to see if the KFLOP device is still present.  If you just unplug the USB and Re-connect it without cycling power on KFLOP does the system still function?
> >  
> > Thanks
> > TK  
> >
> >
> > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> >
> >
> > From: morgtod <todmorg@>
> > Subject: [DynoMotion] Re: Unexpected overflow
> > To: DynoMotion@yahoogroups.com
> > Date: Wednesday, July 13, 2011, 7:22 PM
> >
> >
> >  
> >
> >
> >
> > I set the corner tolerance from .0002 to 0, now it works. I didn't realize there was a patch, where is it located???
> >
> > Next odd behavior, I get random usb disconnects from the Kflop, the Kflop needs to be rebooted when this happens, and it cannot be done with a Reboot!
> >
> > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > >
> > > Hi Todd,
> > >  
> > > There is no line limit in KMotionCNC.  It sounds like a bug on our end.  V4.25 has an issue with the new corner rounding unless you have copied in the patched DLL.  If you set the Corner Tolerance to 0 there will be no corner rounding and no issue.
> > >  
> > > If that doesn't help can you send me the GCode along with your settings (the simplest it to send the KMotion\Data directory and your Init.c file.
> > >  
> > > Thanks
> > > TK
> > >  
> > >  
> > >
> > >
> > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > >
> > >
> > > From: morgtod <todmorg@>
> > > Subject: [DynoMotion] Re: Unexpected overflow
> > > To: DynoMotion@yahoogroups.com
> > > Date: Wednesday, July 13, 2011, 6:07 PM
> > >
> > >
> > >  
> > >
> > >
> > >
> > > Also, THe amp draw on the servos is floating between 0 and 4 or 5 amps, the green scales float low with ocasional spikes to 1/3 or 1/2 with rapid speed changes. There is no spike when it stops.
> > >
> > > --- In DynoMotion@yahoogroups.com, "morgtod" <todmorg@> wrote:
> > > >
> > > > KCNC, 4.25, Yes servos, I've raised the following error from 1000 to 10000, I've set the feedrate over ride down to .1, this slows me to about 3ipm, with no change, 127,000 steps per inch, 150 IPM max
> > > > It stops at the same spot, if I'm cutting metal or air.
> > > > I'm not sure if this is a new problem, these are some of the first large files I'm running.
> > > > On one of the G-code files, it stops on gradual contour arc ( always the same spot )
> > > > On another G-code file, it stops in a 1.25" pocket, always in the same spot, even though it has completed 2 other identical pockets already. I am not hitting limits, only the X dro changes color.
> > > >
> > > >
> > > > The last time I had something like this is when I loaded Mach3 on a new computer and forgot to enter the registration codes, it always stopped at the same spot.
> > > >
> > > > Todd
> > > >
> > > >
> > > > --- In DynoMotion@yahoogroups.com, Tom Kerekes <tk@> wrote:
> > > > >
> > > > > Hi Todd,
> > > > > ÃÆ'‚ 
> > > > > Apparently you are getting a Following Error Axis 0.ÃÆ'‚  I'm not sure if that is the problem or that is caused by the possibly abrupt stop because of a buffer issue.
> > > > > ÃÆ'‚ 
> > > > > I assume you are running KMotionCNC?ÃÆ'‚  What Version?
> > > > > ÃÆ'‚ 
> > > > > I assume you have Servos?
> > > > > ÃÆ'‚ 
> > > > > Was it working before?
> > > > > ÃÆ'‚ 
> > > > > What is your Following Error Limit set at?
> > > > > ÃÆ'‚ 
> > > > > Can you describe what type of motion the GCode is doing and what you mean by "changing GCode files?
> > > > > ÃÆ'‚ 
> > > > > Thanks
> > > > > TK
> > > > > ÃÆ'‚ 
> > > > >
> > > > >
> > > > > --- On Wed, 7/13/11, morgtod <todmorg@> wrote:
> > > > >
> > > > >
> > > > > From: morgtod <todmorg@>
> > > > > Subject: [DynoMotion] Unexpected overflow
> > > > > To: DynoMotion@yahoogroups.com
> > > > > Date: Wednesday, July 13, 2011, 5:41 PM
> > > > >
> > > > >
> > > > > ÃÆ'‚ 
> > > > >
> > > > >
> > > > >
> > > > > I am having a strange problem, when I'm running G-code files, they are quitting at the same point in the program. If I change Gcode files, it will quit repeatably like the first file. Its like I'm hitting a # of lines limit or something. It says Unexpected overflow, something, something, try increasing the lookahead buffer. I've done that with no change. In console it says following error, axis 0 disabled. I've tried lowering speeds to almost nothing, run cutting air, loading different files, I'm stumped!!!
> > > > >
> > > > > Todd
> > > > >
> > > >
> > >
> >
>