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Mach4 Stops mid cycle, "Never happened before"
« on: August 26, 2018, 09:17:23 AM »
Hey! have managed to get a problem with my mach4. The program stops in the middle of the cycle, sometimes a few minutes in and sometimes closer to the end of the cycle, and I can not figure out why it does that!
ive tried to start logging to see what it says, but i dont understand the message,
The problem is shown by that line and beyond from that line:
2018-08-26 14: 45: 02,798 - Controller :: RunCanonBuffer called AddStopReportRequest () RunCanon.cpp: 76
It has worked perfectly before? the problem have started just now?

have been thinking about EMI, or if the computer is too slow, I have tried to mount lots of Ferrite cores, but without any results .. any ideas?

the machine uses twisted pairs with shielding grounded to machine chassie (and only in the machine end)
the computer is moved far away from the machine,
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
2018-08-26 14:40:47.721 - Loggging Enabled.
2018-08-26 14:40:53.298 - Spindle speed capped by current range!
2018-08-26 14:40:53.299 - Spindle speed capped by current range!
2018-08-26 14:40:53.328 - API: mcToolPathGenerate() called.
2018-08-26 14:41:00.066 - API: mcCntlRewindFile() called.
2018-08-26 14:41:06.362 - API: mcCntlCycleStart() called.
2018-08-26 14:41:06.464 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-08-26 14:41:06.464 - Signal id 1127, (Jog Enabled), changed from HIGH to LOW.
2018-08-26 14:41:06.465 - S_IDLE_on_exit
2018-08-26 14:41:06.465 - ACTION_start_cycle
2018-08-26 14:41:06.466 - S_FILE_RUNNING_on_entry
2018-08-26 14:41:06.466 - S_FILE_RUNNING2_on_entry
2018-08-26 14:41:06.466 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-08-26 14:41:06.489 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-08-26 14:41:06.530 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-08-26 14:41:06.532 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-08-26 14:41:06.535 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-08-26 14:41:06.535 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-08-26 14:41:06.536 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<
2018-08-26 14:45:02.798 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-08-26 14:45:02.798 - Requesting a stopped report for axis 0 motors.
2018-08-26 14:45:02.798 - Requesting a stopped report for motor 0.
2018-08-26 14:45:02.798 - Requesting a stopped report for axis 1 motors.
2018-08-26 14:45:02.798 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 0
2018-08-26 14:45:02.799 - Requesting a stopped report for motor 1.
2018-08-26 14:45:02.799 - Requesting a stopped report for axis 2 motors.
2018-08-26 14:45:02.799 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 1
2018-08-26 14:45:02.799 - Requesting a stopped report for motor 2.
2018-08-26 14:45:02.799 - ESS: Mach requested MSG_REPORT_MOTOR_STOP Motor 2
2018-08-26 14:45:02.799 - Waiting on SetStill...
2018-08-26 14:45:02.974 - ESS: Motor 2 Still
2018-08-26 14:45:02.999 - ESS: Motor 0 Still
2018-08-26 14:45:02.999 - ESS: Motor 1 Still
2018-08-26 14:45:02.999 - All motors marked as still.
2018-08-26 14:45:02.999 - Waiting on SetStill is Done!
2018-08-26 14:45:03.001 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-08-26 14:45:03.001 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-08-26 14:45:03.002 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-08-26 14:45:04.488 - Done. Spindle.cpp:356
2018-08-26 14:45:04.488 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-08-26 14:45:04.499 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-08-26 14:45:04.499 - S_FILE_RUNNING2_on_exit
2018-08-26 14:45:04.499 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-08-26 14:45:04.499 - S_FILE_RUNNING_on_exit
2018-08-26 14:45:04.500 - ACTION_stop
2018-08-26 14:45:04.523 - S_IDLE_on_entry


Offline mark4

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Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #1 on: August 28, 2018, 08:27:14 PM »
well you certainty have some event happening. have you tried another program and see if it does the same thing. also can you tell where in the Gcode its happening, you said its random but i am wondering if you are calling for something specific in Gcode that happens before this happens. also check all you wires to limits and estop to make sure they are connected well one loose wire can cause no end to trouble.
 
Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #2 on: September 07, 2018, 08:33:57 AM »
I've rewired every cable in the whole machine and moved the control electronics to their own control cabinet to separate stepper motor drivers and the Ethernet smoothstepper card along with the BOB boards that also are grounded with computer and cabinets, ensuring that there are no ground loops

I'm using only shielded cables that are grounded in the signal end for everything, home switches, VFD USB rs485 communication, motor cables, spindle power cable and so on.

I've upgraded the computer to:
Intel i5 6500 3.2Ghz
16GB 1600MHz Ram
128GB SSD Drive,

Mach 4 is the only thing that is installed on the computer, along with drivers, and other necessary things

I've followed the guide for "how to run mach 4 reliable"

I've tried to change the buffer size and Plugin frequency in ESS plugin Configuration under the "General Tab"
following recommended values.

 I can send the gcode file privately. for closer inspection, I use the Fusion 360 and the Postprocessor for mach 3 and have never experienced any problems before? The problem usually occurs at line 17000-19000 as the timeline change says in the log file,

can also see a sudden jump on the line viewing window from line 5000 up to 20000 and back again and when it happens and then the gcode rewinds. spindle still running, is just like the machine stops moving for a second and then moves on but only sometimes, and then that happens again and it locks up, but mach is still operational and I can jog the machine and everything after I reset the E-stop condition

Log file "Try 1" fault occours between 19sec and 36sec

2018-09-07 13:29:32.308 - Loggging Enabled.
2018-09-07 13:29:35.762 - API: mcCntlCycleStart() called.
2018-09-07 13:29:35.863 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:29:35.863 - S_IDLE_on_exit
2018-09-07 13:29:35.863 - ACTION_start_cycle
2018-09-07 13:29:35.864 - S_FILE_RUNNING_on_entry
2018-09-07 13:29:35.864 - S_FILE_RUNNING2_on_entry
2018-09-07 13:29:35.864 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:29:42.178 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 0.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 1.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 2.
2018-09-07 13:29:42.178 - Waiting on SetStill...
2018-09-07 13:29:42.586 - All motors marked as still.
2018-09-07 13:29:42.586 - Waiting on SetStill is Done!
2018-09-07 13:29:42.588 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:29:42.588 - 
2018-09-07 13:29:42.588 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.588 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Required notification.

2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Done notification.

2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:29:42.591 - >>>>> ESS received a Tool Change Done notification.

2018-09-07 13:29:42.591 - 
2018-09-07 13:29:42.591 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.591 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.594 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:29:42.594 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:29:42.594 - 
2018-09-07 13:29:42.594 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.594 -    >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:29:42.595 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:29:42.610 - All motors marked as still.
2018-09-07 13:29:42.661 - 
2018-09-07 13:29:42.661 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.661 -    >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:36:06.139 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 0.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 1.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 2.
2018-09-07 13:36:06.140 - Waiting on SetStill...
2018-09-07 13:36:06.521 - All motors marked as still.
2018-09-07 13:36:06.521 - Waiting on SetStill is Done!
2018-09-07 13:36:06.522 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:36:06.522 - 
2018-09-07 13:36:06.522 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:36:06.522 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:36:06.522 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:36:06.522 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:36:08.015 - Done. Spindle.cpp:356
2018-09-07 13:36:08.015 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:36:08.026 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:36:08.026 - S_FILE_RUNNING2_on_exit
2018-09-07 13:36:08.026 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:36:08.026 - S_FILE_RUNNING_on_exit
2018-09-07 13:36:08.026 - ACTION_stop
2018-09-07 13:36:08.042 - S_IDLE_on_entry
............................................................................



Log file "Try 2" With Stop/Emergency button hit. problem occurs between 46sec and 53sec

2018-09-07 13:46:05.722 - Loggging Enabled.
2018-09-07 13:46:14.626 - API: mcCntlCycleStart() called.
2018-09-07 13:46:14.727 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:46:14.727 - Signal id 1127, (Jog Enabled), changed from HIGH to LOW.
2018-09-07 13:46:14.727 - S_IDLE_on_exit
2018-09-07 13:46:14.727 - ACTION_start_cycle
2018-09-07 13:46:14.728 - S_FILE_RUNNING_on_entry
2018-09-07 13:46:14.728 - S_FILE_RUNNING2_on_entry
2018-09-07 13:46:14.728 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:46:21.211 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 0.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 1.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 2.
2018-09-07 13:46:21.211 - Waiting on SetStill...
2018-09-07 13:46:21.475 - All motors marked as still.
2018-09-07 13:46:21.475 - Waiting on SetStill is Done!
2018-09-07 13:46:21.476 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:46:21.476 - 
2018-09-07 13:46:21.476 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.476 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.512 - All motors marked as still.
2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Required notification.

2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Done notification.

2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:46:21.515 - >>>>> ESS received a Tool Change Done notification.

2018-09-07 13:46:21.515 - 
2018-09-07 13:46:21.515 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.515 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.516 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:46:21.516 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:46:21.516 - 
2018-09-07 13:46:21.516 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.516 -    >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:46:21.516 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:46:21.613 - 
2018-09-07 13:46:21.613 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.613 -    >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:53:56.933 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 0.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 1.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:53:56.934 - Requesting a stopped report for motor 2.
2018-09-07 13:53:56.934 - Waiting on SetStill...
2018-09-07 13:53:57.171 - All motors marked as still.
2018-09-07 13:53:57.171 - Waiting on SetStill is Done!
2018-09-07 13:53:57.172 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:53:57.172 - 
2018-09-07 13:53:57.172 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:53:57.172 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:53:57.173 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:53:57.173 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:53:58.669 - Done. Spindle.cpp:356
2018-09-07 13:53:58.670 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:53:58.679 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:53:58.679 - S_FILE_RUNNING2_on_exit
2018-09-07 13:53:58.679 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:53:58.679 - S_FILE_RUNNING_on_exit
2018-09-07 13:53:58.679 - ACTION_stop
2018-09-07 13:53:58.696 - S_IDLE_on_entry
2018-09-07 13:54:14.554 - API: mcScriptExecute() called. filename "m5.mcs" async 0
2018-09-07 13:54:14.556 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.556 - 
2018-09-07 13:54:14.556 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.556 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.582 - API: mcCntlCycleStop() called.
2018-09-07 13:54:14.585 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.586 - 
2018-09-07 13:54:14.586 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.586 -    >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.586 - 
2018-09-07 13:54:14.586 -    $$$ ESS: Mach4 had a Cycle Stop - Force Output Stop Sates Now
2018-09-07 13:54:14.586 -    $$$ ESS: Finished processing the Stop Event
2018-09-07 13:54:14.586 - 




Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #3 on: September 07, 2018, 11:09:01 AM »
Hello again! I tried to run the code again and there is no specific line in the gcode that seems to be the problem?
The problem is that it can´t handle more than 6-7 minutes in running state..
Pressed cycle start and waited for the problem to happen and it happened, this time I was able to roughly see what line it stopped working at. close to line 20000 but that´s not always at that line. sometimes it happens at line 17840 and sometimes at line 25123 and every line between so it´s not consistent.

Scrolled down to somewhere around line 14000 and chose to "run from here", and it seemed to work like it should, Runs to the end of the program and then return to Machine Zero.

It´s a very small object with very complex engraving, but shouldn't be too much for the computer/ESS?  

something is wrong with mach/windows 10? timing out?

the Ethernet port is not allowed to sleep, HDD/Screen isn't allowed to go to sleep either? mach is prioritized as highest possible





Offline Stuart

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Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #4 on: September 07, 2018, 12:20:59 PM »
Is your licence installed correctly ?

That’s the what happens if the licence file is not installed

Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #5 on: September 07, 2018, 12:22:53 PM »
Yes it’s licensed as a hobby license, and it’s active. I think the limit of lines is set to 500 when using the demo version

Offline Stuart

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Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #6 on: September 07, 2018, 12:53:39 PM »
Ok

Then apart from your pc running short of ram , or a corrupt install of mach4 I cannot help sorry

Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #7 on: September 07, 2018, 12:57:13 PM »
Hi,

Quote
I think the limit of lines is set to 500 when using the demo version
No, the 500 line limit applies to Mach3 when in Demo mode.
Mach4 will run for six minutes before shutting down in Demo mode. Given the timing of the fault I wondered as Stuart did if your licensing was correct.
Try Help/About just to double check that the license file has not got screwed up.

Craig
My wife left with my best friend...
     and I miss him!
Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #8 on: September 07, 2018, 01:03:03 PM »
Absolutely, I’ll check soon
Re: Mach4 Stops mid cycle, "Never happened before"
« Reply #9 on: September 07, 2018, 01:28:38 PM »
I run another program now, and it just went past 18minutes  @37000 lines and  the program in total is 100000 lines, it’s not as dense as the other program that I have problem with. I’m gonna wait and see if this program
Makes it,

 I don’t know if Mach and my setup is up for the job with that fast running code for that file that I have problem with
and I’m also currently remaking the model and cam processing for the other file to see if something happend in fusion from the beginning? License seems to work anyway,