Thread to shoulder, custom thread, multi-start threads (and menu to use).

README.md

@@ -1,3 +1,70 @@
+## Update.
+Fixed a bug I introduced earlier that causes the auto retract to lose sync on some threads (never edit code when you're tired).
+Added deceleration to end of auto retract.
+## Added multistart threads (see below)
+To function this adds one extra step to the shoulder operation to select the number of starts.
+## Added thread to shoulder, custom thread pitches and angular position of spindle.
+Allows the threading to shoulder (with retraction to start of thread without requiring the spindle to be rotated).
+Allows the setting of custom thread pitches from 0.01mm to 9.99mm.
+Can display the angular position of the spindle instead of RPM.
+
+The three modes are accessed via an options menu by pressing "Set".
+
+You can now cycle between the options using the "+" and "-" buttons.
+
+Press "Set" to select one (options will time out after a few seconds).
+
+
+#### Custom Thread ("CUSt tHd").
+Left hand display shows "Ct" and the first digit of the pitch will be flashing. 
+
+Use "+" and "-" to change this, press "Set" to move to the next digit, repeat for all digits.
+
+When the final digit has been entered the display will return to the normal threading display but using the new pitch.
+
+(At any point while "Ct" is displayed pressing the power button will exit the mode).
+
+#### Thread to shoulder ("SHOULdEr").
+Display shows Multi 1 ("MULtI 1") this is the number of starts the thread has, use the + & - keys to change this value and press Set to accept.
+(A value of '1' is a normal single start thread)
+
+Display shows Go Shoulder ("GO SHLdr"), move the carriage to the shoulder position (either manually or by engaging the half nuts and driving the spindle).
+
+If you haven't already engage the half nuts - they MUST now remain engaged for the duration of the threading operation.
+
+Press "Set" to mark the shoulder position. Display will now show Go Start ("GO StArt").
+
+Move the carriage by using the spindle to the start position of the thread and press "Set" once there.
+
+You've now marked the shoulder and start positions of the thread so we can cut the thread.
+
+Display shows Begin ("BEGIN n.x") until the spindle starts to rotate, where 'n' is the start number and x is the number of starts. For normal single start threads this will show "1.1".
+Each subsequent loop will increment the 'n' value and the thread will start at the new position. When all starts have been machined n will loop back to 1 and the process can be repeated. 
+
+Cut one pass, when the carriage reaches the shoulder it will stop and the display will show Stop ("StOP").
+
+Stop the spindle, once it reaches zero rpm the display will show Retract ("rEtrACt").
+You should now retract the tool from the work and press either the "+" button or the "set" button which will cause the carriage to return to the start position.
+Whilst the carriage is moving the display will show Wait ("WAIt")
+
+Display once again shows Begin. Repeat the above until you've cut your thread.
+
+When the spindle is at zero RPM the display will have the prefix "SH" to remind you you're in Cut-to-shoulder mode. 
+Press "Pwr" once to exit.
+
+#### Position ("POSItION").
+
+RPM is replaced by the angular position of the spindle. 
+
+Exit by going back into the menu and selecting RPM.
+
+
+# Notes
+Retraction speed is set in configuration.h "retractSpeed" - currently set to 100rpm.
+
+Display brightness can be changed when in "powered off" mode using the + & - buttons.
+
+
 # Clough42 Lathe Electronic Leadscrew Controller
 
 This is the firmware for a lathe electronic leadscrew controller.  The goal is to replace the change

els-f280049c/Configuration.h

@@ -40,11 +40,11 @@
 //================================================================================
 
 // For Imperial leadscrews: pitch in Threads Per Inch (TPI)
-#define LEADSCREW_TPI 12
+//#define LEADSCREW_TPI 12
 
 // For metric leadscrews: pitch in hundredths of a millimeter (HMM)
 // Example: 200hmm = 2mm
-//#define LEADSCREW_HMM 200
+#define LEADSCREW_HMM 300
 
 
 
@@ -82,8 +82,6 @@
 #define USE_ALARM_PIN
 
 
-
-
 //================================================================================
 //                                 ENCODER
 //
@@ -96,13 +94,43 @@
 //================================================================================
 
 // Encoder resolution (counts per revolution)
-#define ENCODER_RESOLUTION 4096
+#define ENCODER_RESOLUTION 4000
 
 // Which encoder input to use
 #define ENCODER_USE_EQEP1
 //#define ENCODER_USE_EQEP2
 
 
+//================================================================================
+// power on state when booted
+//================================================================================
+
+#define START_POWER_ON  false
+
+
+//================================================================================
+// backlash value
+// This fixes an issue (which may only apply to me) in that the encoder at certain
+// positions 'dithered' causing the stepper to 'vibrate' resulting in noise when the
+// lathe was stopped.
+// This value effectively adds backlash to the system so that the minimum number of
+// steps have to be issued before the motor will move
+// set to zero if not required.
+//================================================================================
+
+#define backlash 2
+
+
+//================================================================================
+// for automatic retraction we can set the maximum rpm of the leadscrew.
+// The speed shouldn't be too high since the leadscrew doesn't decelerate plus
+// high speeds could result in missed steps and loss of sync between spindle and leadscrew
+// (slightly odd equation layout to stop it issuing integer overflow warnings)
+//================================================================================
+
+#define leadscrewRPM(rpm) ((200000 * 60) / rpm) / (STEPPER_MICROSTEPS * STEPPER_RESOLUTION);
+// default to 200rpm
+const int32 retractSpeed = leadscrewRPM( 100 );
 
 
 //================================================================================
@@ -117,7 +145,6 @@
 
 
 
-
 //================================================================================
 //                                HARDWARE
 //

els-f280049c/ControlPanel.cpp

@@ -185,6 +185,28 @@ void ControlPanel :: decomposeRPM()
         this->sevenSegmentData[i] = (rpm == 0 && i != 3) ? 0 : lcd_char(rpm % 10);
         rpm = rpm / 10;
     }
+
+    // add a 2 char prefix to show mode if rpm is zero
+    if (this->rpm == 0)
+    {
+        this->sevenSegmentData[0] = this->curMode[0];
+        this->sevenSegmentData[1] = this->curMode[1];
+    }
+}
+
+void ControlPanel :: decomposeSpindleAngle()
+{
+    Uint16 angle = this->spindleAngle;
+    int i;
+
+    for(i=3; i>=0; i--)
+    {
+        if (i == 2 )
+              this->sevenSegmentData[i] = lcd_char(angle % 10) | lcd_char(10);
+        else
+            this->sevenSegmentData[i] = (angle == 0 && i != 3) ? 0 : lcd_char(angle % 10);
+        angle = angle / 10;
+    }
 }
 
 void ControlPanel :: decomposeValue()
@@ -199,6 +221,7 @@ void ControlPanel :: decomposeValue()
     }
 }
 
+
 KEY_REG ControlPanel :: readKeys(void)
 {
     SpibRegs.SPICTL.bit.TALK = 1;
@@ -300,11 +323,27 @@ void ControlPanel :: setBrightness( Uint16 brightness )
     this->brightness = brightness;
 }
 
-void ControlPanel :: refresh()
+void ControlPanel :: incBrightness()
+{
+    if (this->brightness < 8)
+        this->brightness++;
+}
+
+void ControlPanel :: decBrightness()
+{
+    if (this->brightness > 1)
+        this->brightness--;
+}
+
+void ControlPanel :: refresh(bool showAngle)
 {
     configureSpiBus();
 
-    decomposeRPM();
+    if ( showAngle )
+        decomposeSpindleAngle();
+    else
+        decomposeRPM();
+
     decomposeValue();
 
     sendData();

els-f280049c/ControlPanel.h

@@ -127,6 +127,8 @@ class ControlPanel
 
     // Current RPM value; 4 decimal digits
     Uint16 rpm;
+    // Current spindle angle value
+    Uint16 spindleAngle;
 
     // Current displayed setting value, 4 digits
     const Uint16 *value;
@@ -150,10 +152,14 @@ class ControlPanel
     // Derived state, calculated internally
     Uint16 sevenSegmentData[8];
 
+    // prefix for mode
+    int curMode[2];
+
     // dummy register, for SPI
     Uint16 dummy;
 
     void decomposeRPM(void);
+    void decomposeSpindleAngle(void);
     void decomposeValue(void);
     KEY_REG readKeys(void);
     Uint16 lcd_char(Uint16 x);
@@ -178,6 +184,9 @@ class ControlPanel
     // set the RPM value to display
     void setRPM(Uint16 rpm);
 
+    // set the spindle angle value to display
+    void setSpindleAngle(Uint16 angle);
+
     // set the value to display
     void setValue(const Uint16 *value);
 
@@ -189,11 +198,19 @@ class ControlPanel
 
     // set a brightness value, 0 (off) to 8 (max)
     void setBrightness(Uint16 brightness);
+    void incBrightness();
+    void decBrightness();
+
+    void showCurMode(Uint16 dig1, Uint16 dig2)   {curMode[0] = dig1; curMode[1] = dig2;}
 
     // refresh the hardware display
-    void refresh(void);
+    void refresh(bool showAngle);
 };
 
+inline void ControlPanel :: setSpindleAngle(Uint16 angle)
+{
+    this->spindleAngle = angle;
+}
 
 inline void ControlPanel :: setRPM(Uint16 rpm)
 {

els-f280049c/Core.cpp

@@ -41,7 +41,7 @@ Core :: Core( Encoder *encoder, StepperDrive *stepperDrive )
     this->previousFeedDirection = 0;
     this->previousFeed = NULL;
 
-    this->powerOn = true; // default to power on
+    setPowerOn(START_POWER_ON);  // initial power on state
 }
 
 void Core :: setReverse(bool reverse)
@@ -64,6 +64,3 @@ void Core :: setPowerOn(bool powerOn)
 
 
 
-
-
-

els-f280049c/Core.h

@@ -59,6 +59,7 @@ class Core
 public:
     Core( Encoder *encoder, StepperDrive *stepperDrive );
 
+    void reset(void);
     void setFeed(const FEED_THREAD *feed);
     void setReverse(bool reverse);
     Uint16 getRPM(void);
@@ -67,6 +68,15 @@ class Core
     bool isPowerOn();
     void setPowerOn(bool);
 
+    void setShoulder( void )                            { stepperDrive->setShoulder(); }
+    void setStart( void )                               { stepperDrive->setStart(); }
+    void setStartOffset( float normalisedAngleOffset );
+    void beginThreadToShoulder( bool start )            { stepperDrive->beginThreadToShoulder(start); }
+    void moveToStart( void );
+    bool isAtShoulder( void )                           { return stepperDrive->isAtShoulder(); }
+    bool isAtStart( void )                              { return stepperDrive->isAtStart(); }
+    void resetToShoulder( void );
+
     void ISR( void );
 };
 
@@ -103,6 +113,27 @@ inline int32 Core :: feedRatio(Uint32 count)
 #endif // USE_FLOATING_POINT
 }
 
+
+inline void Core :: resetToShoulder( void )
+{
+    float stepsPerUnitPitch = (float) ENCODER_RESOLUTION * this->feed;
+    stepperDrive->resetToShoulder(stepsPerUnitPitch);
+}
+
+inline void Core :: setStartOffset( float normalisedAngleOffset )
+{
+    int32 offset = ((float) ENCODER_RESOLUTION) * normalisedAngleOffset * this->feed;
+    stepperDrive->setStartOffset(offset);
+}
+
+inline void Core :: moveToStart( )
+{
+    int32 stepsPerUnitPitch = (float) ENCODER_RESOLUTION * this->feed;
+    stepperDrive->moveToStart(stepsPerUnitPitch);
+}
+
+
+
 inline void Core :: ISR( void )
 {
     if( this->feed != NULL ) {
@@ -114,10 +145,12 @@ inline void Core :: ISR( void )
         stepperDrive->setDesiredPosition(desiredSteps);
 
         // compensate for encoder overflow/underflow
-        if( spindlePosition < previousSpindlePosition && previousSpindlePosition - spindlePosition > encoder->getMaxCount()/2 ) {
+        if( spindlePosition < previousSpindlePosition && previousSpindlePosition - spindlePosition > encoder->getMaxCount()/2 )
+        {
             stepperDrive->incrementCurrentPosition(-1 * feedRatio(encoder->getMaxCount()));
         }
-        if( spindlePosition > previousSpindlePosition && spindlePosition - previousSpindlePosition > encoder->getMaxCount()/2 ) {
+        if( spindlePosition > previousSpindlePosition && spindlePosition - previousSpindlePosition > encoder->getMaxCount()/2 )
+        {
             stepperDrive->incrementCurrentPosition(feedRatio(encoder->getMaxCount()));
         }
 
@@ -137,4 +170,5 @@ inline void Core :: ISR( void )
 }
 
 
+
 #endif // __CORE_H