PCB Milling Feed Rate issue

Moderators: TomKerekes, dynomotion

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jpbarad7
Posts: 17
Joined: Wed Dec 07, 2022 6:25 pm

PCB Milling Feed Rate issue

Post by jpbarad7 » Sat Mar 22, 2025 5:17 pm

Tom,

I’ve been using my SuperMax knee mill with KFLOP and closed-loop steppers to CNC mill printed circuit boards. I’m running the spindle at 2500 RPM with carbide end mills and drills. At a feed rate of 1 inch per minute, the results are very acceptable (photo attached).
1 ipm.JPG
However, as I increase the feed rate, the circular pads become increasingly irregular — I’ve attached photos at 5 IPM and 20 IPM for comparison.
5 ipm.JPG
20 ipm.JPG
I’ve tried a variety of adjustments but haven’t found anything that allows for higher feed rates without compromising quality.

While I’m fine working at 1 IPM since I don’t plan to produce a large number of PCBs, it would be nice to improve the feed rate if possible.

I suspect this may be a limitation of my hardware, but I’m also curious if there might be something in the configuration or software contributing to the issue.

I’d appreciate any thoughts or suggestions.

Best regards,
Jim
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User avatar
TomKerekes
Posts: 2747
Joined: Mon Dec 04, 2017 1:49 am

Re: PCB Milling Feed Rate issue

Post by TomKerekes » Sat Mar 22, 2025 5:52 pm

Hi Jim,

Hmmm, maybe a lag in the axis positions?

Are the Steppers Closed loop in KFLOP or the Drives?

Please post your Configuration file GCodeConfigCNC.txt, the Initialization C Program, and the GCode and we can look into it.
Regards,

Tom Kerekes
Dynomotion, Inc.
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jpbarad7
Posts: 17
Joined: Wed Dec 07, 2022 6:25 pm

Re: PCB Milling Feed Rate issue

Post by jpbarad7 » Sun Mar 23, 2025 8:29 pm

Thanks for your willingness to help.

My mill uses closed loop steppers controlled only by KFLOP, not by the stepper drivers.

I am using the Mach3 plug in, not KmotionCNC, however, I experience the same issues using KmotionCNC.

This is the GCodeConfigCNC.txt file from the Kmotion data folder:

Code: Select all

m_SetupFile=DefaultKeepOffsetsInches.set
m_ToolFile=Default.tbl
m_GeoFile=
m_Button0=INIT
m_Button1=
m_Button2=
m_Button3=
m_Button4=
m_Button5=
m_Button6=
m_Button7=
m_Button8=
m_Button9=
CommandHistory[0]=g0x0
CommandHistory[1]=g1x3f5
CommandHistory[2]=g1x0f5
CommandHistory[3]=g1x5f5
CommandHistory[4]=m30
CommandHistory[5]=m3s50
CommandHistory[6]=m8
CommandHistory[7]=m7
CommandHistory[8]=m3s100
CommandHistory[9]=m5
m_CommandString=g0x0
m_BreakAngle=  9.000000000000000e+01
m_CollinearTol=  1.000000000000000e-03
m_CornerTol=  1.000000000000000e-03
m_FacetAngle=  1.000000000000000e+00
m_JogSpeed[0]=  1.000000000000000e+00
m_JogSpeed[1]=  1.000000000000000e+00
m_JogSpeed[2]=  1.000000000000000e+00
m_JogSpeed[3]=  1.000000000000000e+01
m_JogSpeed[4]=  1.000000000000000e+01
m_JogSpeed[5]=  1.000000000000000e+01
m_JogSpeed[6]=  1.000000000000000e+00
m_JogSpeed[7]=  1.000000000000000e+00
m_JogSlowPercent=  2.500000000000000e+01
m_HardwareFRORange=  1.000000000000000e+00
m_MaxRapidFRO=  1.000000000000000e+00
m_ArcRadiusTol=  7.000000000000000e-04
m_ArcRSmallTol=  1.000000000000000e-12
m_TPLookahead=  5.000000000000000e-02
m_RadiusC=  0.000000000000000e+00
m_RadiusB=  0.000000000000000e+00
m_RadiusA=  0.000000000000000e+00
m_MaxAccelC=  1.400000000000000e-01
m_MaxAccelB=  1.000000000000000e+01
m_MaxAccelA=  1.000000000000000e+01
m_MaxAccelX=  4.280000000000000e+00
m_MaxAccelY=  4.480000000000000e+00
m_MaxAccelZ=  4.280000000000000e+00
m_MaxAccelU=  1.000000000000000e-02
m_MaxAccelV=  1.000000000000000e-02
m_MaxVelC=  2.900000000000000e-01
m_MaxVelB=  1.000000000000000e+01
m_MaxVelA=  1.000000000000000e+01
m_MaxVelX=  8.500000000000000e-01
m_MaxVelY=  8.500000000000000e-01
m_MaxVelZ=  1.110000000000000e+00
m_MaxVelU=  1.000000000000000e+01
m_MaxVelV=  1.000000000000000e+01
m_CountsPerInchC=  4.270000000000000e+05
m_CountsPerInchB=  1.000000000000000e+02
m_CountsPerInchA=  1.000000000000000e+02
m_CountsPerInchX=  2.335000000000000e+05
m_CountsPerInchY=  2.335000000000000e+05
m_CountsPerInchZ=  1.800000000000000e+05
m_CountsPerInchU=  1.000000000000000e+02
m_CountsPerInchV=  1.000000000000000e+02
m_Step0=  1.000000000000000e-04
m_Step1=  1.000000000000000e-03
m_Step2=  1.000000000000000e-02
m_Step3=  1.000000000000000e-01
m_Step4=  1.000000000000000e+00
m_Step5=  1.000000000000000e+01
m_ReverseRZ=0
m_EnableGamePad=0
m_ZeroUsingFixtures=0
m_ToolLengthImmediately=0
m_ToolTableDoM6=0
m_ConfirmExit=1
m_ArcsToSegs=0
m_DisplayEncoder=0
m_Lathe=0
m_DoRapidsAsFeeds=0
m_DiameterMode=0
m_XPosFront=0
m_SpindleType=1
m_SpindleAxis=3
m_SaveFixtureOnOK=1
m_SpindleUpdateTime=  2.000000000000000e-01
m_SpindleTau=  1.000000000000000e-01
m_SpindleCntsPerRev=  3.200000000000000e+03
Interpreter->McodeActions[0].Action=0
Interpreter->McodeActions[0].dParams[0]=  0.000000000000000e+00
Interpreter->McodeActions[0].dParams[1]=  0.000000000000000e+00
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Interpreter->McodeActions[3].String=C:\Users\jpbar\Documents\JPB-SuperMax-CNC-Mill\JPB SpindleMach3DAC.c
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Interpreter->McodeActions[39].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[39].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[39].String=
Interpreter->McodeActions[40].Action=0
Interpreter->McodeActions[40].dParams[0]=  0.000000000000000e+00
Interpreter->McodeActions[40].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[40].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[40].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[40].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[40].String=
Interpreter->McodeActions[41].Action=2
Interpreter->McodeActions[41].dParams[0]=  1.510000000000000e+02
Interpreter->McodeActions[41].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[41].dParams[2]=  1.500000000000000e+02
Interpreter->McodeActions[41].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[41].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[41].String=
Interpreter->McodeActions[42].Action=0
Interpreter->McodeActions[42].dParams[0]=  1.000000000000000e+00
Interpreter->McodeActions[42].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[42].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[42].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[42].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[42].String=C:\KMotionSrc\C Programs\HaltGCode.c
Interpreter->McodeActions[43].Action=0
Interpreter->McodeActions[43].dParams[0]=  4.600000000000000e+01
Interpreter->McodeActions[43].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[43].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[43].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[43].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[43].String=C:\KMotionSrc\C Programs\Safe Z on Halt Carl.c
Interpreter->McodeActions[44].Action=2
Interpreter->McodeActions[44].dParams[0]=  1.550000000000000e+02
Interpreter->McodeActions[44].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[44].dParams[2]=  1.510000000000000e+02
Interpreter->McodeActions[44].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[44].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[44].String=
Interpreter->McodeActions[45].Action=0
Interpreter->McodeActions[45].dParams[0]=  0.000000000000000e+00
Interpreter->McodeActions[45].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[45].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[45].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[45].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[45].String=
Interpreter->McodeActions[46].Action=0
Interpreter->McodeActions[46].dParams[0]=  0.000000000000000e+00
Interpreter->McodeActions[46].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[46].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[46].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[46].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[46].String=
Interpreter->McodeActions[47].Action=0
Interpreter->McodeActions[47].dParams[0]=  3.000000000000000e+00
Interpreter->McodeActions[47].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[47].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[47].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[47].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[47].String=C:\KMotionSrc\C Programs\BlinkKFLOP.c
Interpreter->McodeActions[48].Action=0
Interpreter->McodeActions[48].dParams[0]=  0.000000000000000e+00
Interpreter->McodeActions[48].dParams[1]=  0.000000000000000e+00
Interpreter->McodeActions[48].dParams[2]=  0.000000000000000e+00
Interpreter->McodeActions[48].dParams[3]=  0.000000000000000e+00
Interpreter->McodeActions[48].dParams[4]=  0.000000000000000e+00
Interpreter->McodeActions[48].String=
m_DialogFace=1
m_SafeZ=  0.000000000000000e+00
m_SafeRelAbs=0
m_DegreesA=1
m_DegreesB=1
m_DegreesC=0
m_UserButtonKeys[0]=120
m_UserButtonKeys[1]=121
m_UserButtonKeys[2]=-1
m_UserButtonKeys[3]=123
m_UserButtonKeys[4]=-1
m_UserButtonKeys[5]=-1
m_UserButtonKeys[6]=-1
m_UserButtonKeys[7]=-1
m_UserButtonKeys[8]=116
m_UserButtonKeys[9]=117
m_VarsFile=
m_ScreenScriptFile=3AxisNoJog.scr
m_DisplayGViewer=1
m_ConfigCheckWord=12345678
/code]



This is my initialization program:

[code]#include "KMotionDef.h"

// Defines KFLOP channels 0-4 as axes X-C
// Disables and Zeros all axes
// Defines axis parameters
// Enables all axes and sets positions to Zero
// Sets them as an XYZAC coordinate system for GCode
// Watchenable loop turns servos ON/OFF when axes are ENABLED/DISABLED
// or when Control Program (i.e. Mach3) is loaded/ended
// Each axis is disabled when a limit switch is tripped
// To reactivate, manually move axis away from switch then reload Control Program

void ServiceWatchdogStatus(void);
void WatchdogTripped(void);
void WatchdogOK(void);
void WatchLimits(void);

#define X 0
#define Y 1
#define Z 2					// Quill
#define C 3					// Knee
#define A 4					// Rotary

#define WATCHDOG_DELAY 2.0 	// Script to disable drives if/when Control Program is closed

int ControlProgramActive = 1;

int XLimit;
int YLimit;
int ZLimit;
int CLimit;

int main() 
{
	DisableAxis(X);
	Zero(X);

	DisableAxis(Y);
	Zero(Y);

	DisableAxis(Z);
	Zero(Z);

	DisableAxis(C);
	Zero(C);

	DisableAxis(A);
	Zero(A);	

FPGA(STEP_PULSE_LENGTH_ADD)=32 + 0x40 + 0x80;	

	ch0->InputMode=ENCODER_MODE;
	ch0->OutputMode=CL_STEP_DIR_MODE;
	ch0->Vel=200000;
	ch0->Accel=1e+06;
	ch0->Jerk=1e+07;
	ch0->P=0;
	ch0->I=0.001;
	ch0->D=0;
	ch0->FFAccel=0;
	ch0->FFVel=0;
	ch0->MaxI=1e+06;
	ch0->MaxErr=1e+09;
	ch0->MaxOutput=1e+06;
	ch0->DeadBandGain=1;
	ch0->DeadBandRange=0;
	ch0->InputChan0=0;
	ch0->InputChan1=0;
	ch0->OutputChan0=56;
	ch0->OutputChan1=0;
	ch0->MasterAxis=-1;
	ch0->LimitSwitchOptions=0x120;
	ch0->LimitSwitchNegBit=136;
	ch0->LimitSwitchPosBit=136;
	ch0->SoftLimitPos=1e+09;
	ch0->SoftLimitNeg=-1e+09;
	ch0->InputGain0=-46;
	ch0->InputGain1=1;
	ch0->InputOffset0=0;
	ch0->InputOffset1=0;
	ch0->OutputGain=-1;
	ch0->OutputOffset=0;
	ch0->SlaveGain=1;
	ch0->BacklashMode=BACKLASH_OFF;
	ch0->BacklashAmount=0;
	ch0->BacklashRate=0;
	ch0->invDistPerCycle=1;
	ch0->Lead=0;
	ch0->MaxFollowingError=5000;
	ch0->StepperAmplitude=20;

	ch0->iir[0].B0=1;
	ch0->iir[0].B1=0;
	ch0->iir[0].B2=0;
	ch0->iir[0].A1=0;
	ch0->iir[0].A2=0;

	ch0->iir[1].B0=1;
	ch0->iir[1].B1=0;
	ch0->iir[1].B2=0;
	ch0->iir[1].A1=0;
	ch0->iir[1].A2=0;

	ch0->iir[2].B0=0.00075647;
	ch0->iir[2].B1=0.00151294;
	ch0->iir[2].B2=0.00075647;
	ch0->iir[2].A1=1.88998;
	ch0->iir[2].A2=-0.89301;
	


	ch1->InputMode=ENCODER_MODE;
	ch1->OutputMode=CL_STEP_DIR_MODE;
	ch1->Vel=200000;
	ch1->Accel=1e+06;
	ch1->Jerk=1e+07;
	ch1->P=0;
	ch1->I=0.001;
	ch1->D=0;
	ch1->FFAccel=0;
	ch1->FFVel=0;
	ch1->MaxI=1e+06;
	ch1->MaxErr=1e+09;
	ch1->MaxOutput=1e+06;
	ch1->DeadBandGain=1;
	ch1->DeadBandRange=0;
	ch1->InputChan0=1;
	ch1->InputChan1=0;
	ch1->OutputChan0=57;
	ch1->OutputChan1=0;
	ch1->MasterAxis=-1;
	ch1->LimitSwitchOptions=0x120;
	ch1->LimitSwitchNegBit=137;
	ch1->LimitSwitchPosBit=137;
	ch1->SoftLimitPos=1e+09;
	ch1->SoftLimitNeg=-1e+09;
	ch1->InputGain0=46;
	ch1->InputGain1=1;
	ch1->InputOffset0=0;
	ch1->InputOffset1=0;
	ch1->OutputGain=-1;
	ch1->OutputOffset=0;
	ch1->SlaveGain=1;
	ch1->BacklashMode=BACKLASH_OFF;
	ch1->BacklashAmount=0;
	ch1->BacklashRate=0;
	ch1->invDistPerCycle=1;
	ch1->Lead=0;
	ch1->MaxFollowingError=2500;
	ch1->StepperAmplitude=20;

	ch1->iir[0].B0=1;
	ch1->iir[0].B1=0;
	ch1->iir[0].B2=0;
	ch1->iir[0].A1=0;
	ch1->iir[0].A2=0;

	ch1->iir[1].B0=1;
	ch1->iir[1].B1=0;
	ch1->iir[1].B2=0;
	ch1->iir[1].A1=0;
	ch1->iir[1].A2=0;

	ch1->iir[2].B0=0.779671;
	ch1->iir[2].B1=-1.55685;
	ch1->iir[2].B2=0.779671;
	ch1->iir[2].A1=1.55685;
	ch1->iir[2].A2=-0.559341;



	ch2->InputMode=ENCODER_MODE;
	ch2->OutputMode=CL_STEP_DIR_MODE;
	ch2->Vel=200000;
	ch2->Accel=1e+06;
	ch2->Jerk=1e+07;
	ch2->P=0;
	ch2->I=0.001;
	ch2->D=0;
	ch2->FFAccel=0;
	ch2->FFVel=0;
	ch2->MaxI=1e+06;
	ch2->MaxErr=1e+09;
	ch2->MaxOutput=1e+06;
	ch2->DeadBandGain=1;
	ch2->DeadBandRange=0;
	ch2->InputChan0=2;
	ch2->InputChan1=0;
	ch2->OutputChan0=58;
	ch2->OutputChan1=0;
	ch2->MasterAxis=-1;
	ch2->LimitSwitchOptions=0x120;
	ch2->LimitSwitchNegBit=138;
	ch2->LimitSwitchPosBit=138;
	ch2->SoftLimitPos=1e+09;
	ch2->SoftLimitNeg=-1e+09;
	ch2->InputGain0=-35.45;
	ch2->InputGain1=1;
	ch2->InputOffset0=0;
	ch2->InputOffset1=0;
	ch2->OutputGain=-1;
	ch2->OutputOffset=0;
	ch2->SlaveGain=1;
	ch2->BacklashMode=BACKLASH_OFF;
	ch2->BacklashAmount=0;
	ch2->BacklashRate=0;
	ch2->invDistPerCycle=1;
	ch2->Lead=0;
	ch2->MaxFollowingError=2500;
	ch2->StepperAmplitude=20;

	ch2->iir[0].B0=1;
	ch2->iir[0].B1=0;
	ch2->iir[0].B2=0;
	ch2->iir[0].A1=0;
	ch2->iir[0].A2=0;

	ch2->iir[1].B0=1;
	ch2->iir[1].B1=0;
	ch2->iir[1].B2=0;
	ch2->iir[1].A1=0;
	ch2->iir[1].A2=0;

	ch2->iir[2].B0=0.000768809;
	ch2->iir[2].B1=0.00153762;
	ch2->iir[2].B2=0.000768809;
	ch2->iir[2].A1=1.92081;
	ch2->iir[2].A2=-0.923885;
	


	ch3->InputMode=ENCODER_MODE;
	ch3->OutputMode=CL_STEP_DIR_MODE;
	ch3->Vel=100000;
	ch3->Accel=75000;
	ch3->Jerk=1e+06;
	ch3->P=0;
	ch3->I=0.001;
	ch3->D=0;
	ch3->FFAccel=0;
	ch3->FFVel=0;
	ch3->MaxI=1e+06;
	ch3->MaxErr=1e+09;
	ch3->MaxOutput=1e+06;
	ch3->DeadBandGain=1;
	ch3->DeadBandRange=0;
	ch3->InputChan0=3;
	ch3->InputChan1=0;
	ch3->OutputChan0=59;
	ch3->OutputChan1=0;
	ch3->MasterAxis=-1;
	ch3->LimitSwitchOptions=0x120;
	ch3->LimitSwitchNegBit=139;
	ch3->LimitSwitchPosBit=139;
	ch3->SoftLimitPos=1e+09;
	ch3->SoftLimitNeg=-1e+09;
	ch3->InputGain0=-85.3;
	ch3->InputGain1=1;
	ch3->InputOffset0=0;
	ch3->InputOffset1=0;
	ch3->OutputGain=-1;
	ch3->OutputOffset=0;
	ch3->SlaveGain=1;
	ch3->BacklashMode=BACKLASH_OFF;
	ch3->BacklashAmount=0;
	ch3->BacklashRate=0;
	ch3->invDistPerCycle=1;
	ch3->Lead=0;
	ch3->MaxFollowingError=10000;
	ch3->StepperAmplitude=20;

	ch3->iir[0].B0=1;
	ch3->iir[0].B1=0;
	ch3->iir[0].B2=0;
	ch3->iir[0].A1=0;
	ch3->iir[0].A2=0;

	ch3->iir[1].B0=1;
	ch3->iir[1].B1=0;
	ch3->iir[1].B2=0;
	ch3->iir[1].A1=0;
	ch3->iir[1].A2=0;

	ch3->iir[2].B0=0.000768809;
	ch3->iir[2].B1=0.00153762;
	ch3->iir[2].B2=0.000768809;
	ch3->iir[2].A1=1.92081;
	ch3->iir[2].A2=-0.923885;
	

	
	ch4->InputMode=NO_INPUT_MODE;
	ch4->OutputMode=STEP_DIR_MODE;
	ch4->Vel=40000;
	ch4->Accel=400000;
	ch4->Jerk=4e+06;
	ch4->P=0.2;
	ch4->I=0;
	ch4->D=0;
	ch4->FFAccel=0;
	ch4->FFVel=0;
	ch4->MaxI=200;
	ch4->MaxErr=200;
	ch4->MaxOutput=200;
	ch4->DeadBandGain=1;
	ch4->DeadBandRange=0;
	ch4->InputChan0=4;
	ch4->InputChan1=1;
	ch4->OutputChan0=63;
	ch4->OutputChan1=1;
	ch4->MasterAxis=-1;
	ch4->LimitSwitchOptions=0x120;
	ch4->LimitSwitchNegBit=0;
	ch4->LimitSwitchPosBit=0;
	ch4->SoftLimitPos=1e+09;
	ch4->SoftLimitNeg=-1e+09;
	ch4->InputGain0=0;
	ch4->InputGain1=1;
	ch4->InputOffset0=0;
	ch4->InputOffset1=0;
	ch4->OutputGain=1;
	ch4->OutputOffset=0;
	ch4->SlaveGain=1;
	ch4->BacklashMode=BACKLASH_OFF;
	ch4->BacklashAmount=0;
	ch4->BacklashRate=0;
	ch4->invDistPerCycle=1;
	ch4->Lead=0;
	ch4->MaxFollowingError=1000000000;
	ch4->StepperAmplitude=250;

	ch4->iir[0].B0=1;
	ch4->iir[0].B1=0;
	ch4->iir[0].B2=0;
	ch4->iir[0].A1=0;
	ch4->iir[0].A2=0;

	ch4->iir[1].B0=1;
	ch4->iir[1].B1=0;
	ch4->iir[1].B2=0;
	ch4->iir[1].A1=0;
	ch4->iir[1].A2=0;

	ch4->iir[2].B0=1;
	ch4->iir[2].B1=0;
	ch4->iir[2].B2=0;
	ch4->iir[2].A1=0;
	ch4->iir[2].A2=0;


	EnableAxisDest(X,0);
	EnableAxisDest(Y,0);
	EnableAxisDest(Z,0);
	EnableAxisDest(C,0);
	EnableAxisDest(A,0);
	
	DefineCoordSystem6(0,1,2,4,-1,3);
	
	
	for (;;)  							// loop forever
	{
		XLimit = ReadBit(136);
		YLimit = ReadBit(137);
		ZLimit = ReadBit(138);
		CLimit = ReadBit(139);
		
		if (!XLimit || !YLimit || !ZLimit || !CLimit)
		{
			WatchLimits();
		}

		WaitNextTimeSlice();
		ServiceWatchdogStatus();
				
		if  (ControlProgramActive &&	// ControlProgramActive when loaded
		    (ch0->Enable) &&
		    (ch1->Enable) &&
		    (ch2->Enable) &&		    		    
		    (ch3->Enable) &&
		    (ch4->Enable))				// Enables stepper drivers IF ALL axes are enabled
		
			SetBit(155);		
		else
			ClearBit(155);				// Disables stepper drivers if ANY axis is disabled
	}
		
	return 0;
}


void ServiceWatchdogStatus(void)
{
	static int Alive=FALSE;
	static int PrevStatusRequestCounter=-1;
	static double WatchdogTime=0;
	double T=Time_sec();
	
	// check if Host is requesting Status
	if (StatusRequestCounter != PrevStatusRequestCounter)
	{
		// yes, save time 
		WatchdogTime = T + WATCHDOG_DELAY;
		PrevStatusRequestCounter=StatusRequestCounter;
		if (!Alive) WatchdogOK();
		Alive=TRUE;
	}
	else
	{
		if (T > WatchdogTime) 	 // time to trigger?
		{
			if (Alive) WatchdogTripped();
			Alive=FALSE; 
		}
	}
}


void WatchdogOK(void)			// Trips when Mach3/KMotionCNC is open
{
	ClearBit(47);  				// KFLOP LED off
	Delay_sec(1);
	SetBit(47);
	Delay_sec(1);
	
	ControlProgramActive = 1;
}


void WatchdogTripped(void)		// Trips when Mach3/KMotionCNC is closed 
{	
	ClearBit(46);  				// KFLOP LED off
	Delay_sec(1);
	SetBit(46);
	Delay_sec(1);
	
	ControlProgramActive = 0;	// Keeps forever loop from re-enabling drives 
								// with 'SetBit(155)'
}


void WatchLimits(void)
{
	if (XLimit == 0)
	{
		ClearBit(155);
		DisableAxis(X);
	}
	
	if (YLimit == 0)
	{
		ClearBit(155);
		DisableAxis(Y);
	}
	
	if (ZLimit == 0)
	{
		ClearBit(155);
		DisableAxis(Z);
	}
	
	if (CLimit == 0)
	{
		ClearBit(155);
		DisableAxis(C);
	}

	ClearBit(150);				// Disables VFD and stops spindle motor
	ClearBit(151);
}
/code]


Lastly, this is the Gcode file for the program used to mill the speed test PCB file shown in the previous photos:

[code](SPEED TEST)
(MACHINE)
(  DESCRIPTION JPB SUPERMAX)
(T9 D=0.02 CR=0.1 TAPER=10DEG - ZMIN=-0.007 - TAPERED MILL)
G90 G94 G91.1 G40 G49 G17
G0 Z0.4

(CONTOUR 1)
S100 M3
G4 P10
G90
G54
M7
M8
G0 X0.6839 Y0.1161
G43 Z0.4 H9
G0 Z0.2
G1 Z0.004 F1.
Z-0.007
X0.4339 Y-0.1339
G2 X0.3661 Y-0.0661 I-0.0339 J0.0339
G1 X0.6661 Y0.2339
G2 X0.7339 I0.0339 J-0.0339
Y0.1661 I-0.0339 J-0.0339
G1 X0.6839 Y0.1161
G0 Z0.2
X0.7525 Y0.0932
G1 Z0.004 F1.
Z-0.007
X0.7521 Y0.0966
X0.752 Y0.1
Y0.2
G2 X0.848 I0.048 J0.
G1 Y0.1
G2 X0.7525 Y0.0932 I-0.048 J0.
G0 Z0.2
X0.7713 Y-0.0385
G1 Z0.004 F1.
Z-0.007
G2 X0.8287 Y0.0385 I0.0287 J0.0385
X0.7713 Y-0.0385 I-0.0287 J-0.0385
G0 Z0.2
X0.7659 Y-0.1341
G1 Z0.004 F1.
Z-0.007
G2 X0.8341 Y-0.0665 I0.0341 J0.0338
X0.7659 Y-0.1341 I-0.0341 J-0.0338
G0 Z0.2
Y-0.1659
G1 Z0.004 F1.
Z-0.007
G2 X0.8341 Y-0.2334 I0.0341 J-0.0338
X0.7659 Y-0.1659 I-0.0341 J0.0338
G0 Z0.2
X0.7339 Y-0.166
G1 Z0.004 F1.
Z-0.007
G2 X0.7321 Y-0.2357 I-0.0339 J-0.034
X0.6625 Y-0.23 I-0.0321 J0.0357
G1 X0.6375
G2 X0.5625 I-0.0375 J0.03
G1 X0.4375
G2 X0.3625 Y-0.17 I-0.0375 J0.03
X0.4375 I0.0375 J-0.03
G1 X0.5625
G2 X0.6375 I0.0375 J-0.03
G1 X0.6625
G2 X0.7339 Y-0.166 I0.0375 J-0.03
G0 Z0.2
Y-0.134
G1 Z0.004 F1.
Z-0.007
G2 X0.7 Y-0.148 I-0.0339 J0.034
G1 X0.6
G2 Y-0.052 I0. J0.048
G1 X0.642
G3 X0.652 Y-0.042 I0. J0.01
G1 Y0.
G2 X0.748 I0.048 J0.
G1 Y-0.1
G2 X0.7339 Y-0.134 I-0.048 J0.
G0 Z0.2
X0.4932 Y0.1525
G1 Z0.004 F1.
Z-0.007
G2 X0.4625 Y0.17 I0.0068 J0.0475
G1 X0.4375
G2 X0.43 Y0.1625 I-0.0375 J0.03
G1 Y0.1375
G2 X0.37 Y0.0625 I-0.03 J-0.0375
Y0.1375 I0.03 J0.0375
G1 Y0.1625
G2 X0.3661 Y0.2339 I0.03 J0.0375
X0.4375 Y0.23 I0.0339 J-0.0339
G1 X0.4625
G2 X0.5375 Y0.17 I0.0375 J-0.03
X0.4932 Y0.1525 I-0.0375 J0.03
G0 Z0.4

M9
M5
G0 Z0.4
G0 X0 Y0
M30
/code]

Thank you again!

Jim
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TomKerekes
Posts: 2747
Joined: Mon Dec 04, 2017 1:49 am

Re: PCB Milling Feed Rate issue

Post by TomKerekes » Sun Mar 23, 2025 10:36 pm

Hi Jim,

Here are some thoughts:

The Look ahead/Buffer time is only 0.05 seconds. This should normally be at least 1 second.

The Max Following error setting of 5000 counts corresponds to ~0.02 inches. This is relatively large so if the axes aren't following the trajectory precisely there wouldn't be an error. I'm guessing the errors are on the order of 0.005 inches? That would be around 1200 counts. How low can you set the Max Following error before you detect errors?

You might check the Servo Tuning using the Step Response Screen at similar conditions. Such as:

Feedrate 5ipm -> 20,000 counts/sec
Accel 4.28 inches/sec2 -> 1,000,000 counts/sec2
Jerk infinity 1e8
Move size 0.1 inches -> 23,350 counts

You might consider using lower accelerations. For example a motion of 0.1 inches at 5ipm takes about 1.25 seconds. While the acceleration to 5ipm takes only ~0.02 seconds. So the acceleration could be reduced without significantly reducing throughput.

You might capture the motion with a C Program like CaptureXYMotionPosDest.c to analyze exactly how well the servo is following.

HTH
Regards,

Tom Kerekes
Dynomotion, Inc.
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