Code Notes

Intended audience

This document is a collection of notes about the internals of Machinekit. It is primarily of interest to developers, however much of the information here may also be of interest to system integrators and others who are simply curious about how Machinekit works. Much of this information is now outdated and has never been reviewed for accuracy.

Organization

There will be a chapter for each of the major components of Machinekit, as well as chapter(s) covering how they work together. This document is very much a work in progress, and its layout may change in the future.

Terms and definitions

'AXIS' - An axis is one of the nine degrees of freedom that define a tool position in three-dimensional Cartesian space. Those nine axes are referred to as X, Y, Z, A, B, C, U, V, and W. The linear orthagonal coordinates X, Y, and Z determine where the tip of the tool is positioned. The angular coordinates A, B, and C determine the tool orientation. A second set of linear orthagonal coordinates U, V, and W allows tool motion (typically for cutting actions) relative to the previously offset and rotated axes.

Unfortunately “axis” is also
sometimes used to mean a degree of freedom of the machine itself, such
as the saddle, table, or quill of a Bridgeport type milling machine. On
a Bridgeport this causes no confusion, since movement of the table
directly corresponds to movement along the X axis. However, the
shoulder and elbow joints of a robot arm and the linear actuators of a
hexapod do not correspond to movement along any Cartesian axis, and in
general it is important to make the distinction between the Cartesian
axes and the machine degrees of freedom. In this document, the latter
will be called 'joints', not axes. (The GUIs and some other parts of
the code may not always follow this distinction, but the internals of
the motion controller do.)

'JOINT' - A joint is one of the movable parts of the machine. Joints are distinct from axes, although the two terms are sometimes (mis)used to mean the same thing. In Machinekit, a joint is a physical thing that can be moved, not a coordinate in space. For example, the quill, knee, saddle, and table of a Bridgeport mill are all joints. The shoulder, elbow, and wrist of a robot arm are joints, as are the linear actuators of a hexapod. Every joint has a motor or actuator of some type associated with it. Joints do not necessarily correspond to the X, Y, and Z axes, although for machines with trivial kinematics that may be the case. Even on those machines, joint position and axis position are fundamentally different things. In this document, the terms 'joint' and 'axis' are used carefully to respect their distinct meanings. Unfortunately that isn’t necessarily true everywhere else. In particular, GUIs for machines with trivial kinematics may gloss over or completely hide the distinction between joints and axes. In addition, the ini file uses the term 'axis' for data that would more accurately be described as joint data, such as input and output scaling, etc.
'POSE' - A pose is a fully specified position in 3-D Cartesian space. In the Machinekit motion controller, when we refer to a pose we mean an EmcPose structure, containing three linear coordinates and three angular ones.

Architecture overview

There are four components contained in the Machinekit Architecture: a motion controller (EMCMOT), a discrete IO controller (EMCIO), a task executor which coordinates them (EMCTASK) and several text-mode and graphical User Interfaces. Each of them will be described in the current document, both from the design point of view and from the developers point of view (where to find needed data, how to easily extend/modify things, etc.).

Machinekit software architecture. At the coarsest level, Machinekit is a hierarchy of three controllers: the task level command handler and program interpreter, the motion controller, and the discrete I/O controller. The discrete I/O controller is implemented as a hierarchy of controllers, in this case for spindle, coolant, and auxiliary (e.g., estop, lube) subsystems. The task controller coordinates the actions of the motion and discrete I/O controllers. Their actions are programmed in conventional numerical control "G and M code" programs, which are interpreted by the task controller into NML messages and sent to either the motion or discrete I/O controllers at the appropriate times.

Motion Controller Introduction

The motion controller receives commands from user space modules via a shared memory buffer, and executes those commands in realtime. The status of the controller is made available to the user space modules through the same shared memory area. The motion controller interacts with the motors and other hardware using the HAL (Hardware Abstraction Layer). This document assumes that the reader has a basic understanding of the HAL, and uses terms like HAL pins, HAL signals, etc, without explaining them. For more information about the HAL, see the HAL Manual. Another chapter of this document will eventually go into the internals of the HAL itself, but in this chapter, we only use the HAL API as defined in src/hal/hal.h.

Block diagrams and Data Flow

The following figure is a block diagram of a joint controller. There is one joint controller per joint. The joint controllers work at a lower level than the kinematics, a level where all joints are completely independent. All the data for a joint is in a single joint structure. Some members of that structure are visible in the block diagram, such as coarse_pos, pos_cmd, and motor_pos_fb.

Joint Controller Block Diagram

The above figure shows five of the seven sets of position information that form the main data flow through the motion controller. The seven forms of position data are as follows:

'emcmotStatus->carte_pos_cmd' - This is the desired position, in Cartesian coordinates. It is updated at the traj rate, not the servo rate. In coord mode, it is determined by the traj planner. In teleop mode, it is determined by the traj planner? In free mode, it is either copied from actualPos, or generated by applying forward kins to (2) or (3).
'emcmotStatus->joints[n].coarse_pos' - This is the desired position, in joint coordinates, but before interpolation. It is updated at the traj rate, not the servo rate. In coord mode, it is generated by applying inverse kins to (1) In teleop mode, it is generated by applying inverse kins to (1) In free mode, it is copied from (3), I think.
'emcmotStatus->joints[n].pos_cmd - This is the desired position, in joint coords, after interpolation. A new set of these coords is generated every servo period. In coord mode, it is generated from (2) by the interpolator. In teleop mode, it is generated from (2) by the interpolator. In free mode, it is generated by the free mode traj planner.
'emcmotStatus->joints[n].motor_pos_cmd' - This is the desired position, in motor coords. Motor coords are generated by adding backlash compensation, lead screw error compensation, and offset (for homing) to (3). It is generated the same way regardless of the mode, and is the output to the PID loop or other position loop.
'emcmotStatus->joints[n].motor_pos_fb' - This is the actual position, in motor coords. It is the input from encoders or other feedback device (or from virtual encoders on open loop machines). It is "generated" by reading the feedback device.
'emcmotStatus->joints[n].pos_fb' - This is the actual position, in joint coordinates. It is generated by subtracting offset, lead screw error compensation, and backlash compensation from (5). It is generated the same way regardless of the operating mode.
'emcmotStatus->carte_pos_fb' - This is the actual position, in Cartesian coordinates. It is updated at the traj rate, not the servo rate. Ideally, actualPos would always be calculated by applying forward kinematics to (6). However, forward kinematics may not be available, or they may be unusable because one or more axes aren’t homed. In that case, the options are: A) fake it by copying (1), or B) admit that we don’t really know the Cartesian coordinates, and simply don’t update actualPos. Whatever approach is used, I can see no reason not to do it the same way regardless of the operating mode. I would propose the following: If there are forward kins, use them, unless they don’t work because of unhomed axes or other problems, in which case do (B). If no forward kins, do (A), since otherwise actualPos would never get updated.

Commands

This section simply lists all of the commands that can be sent to the motion module, along with detailed explanations of what they do. The command names are defined in a large typedef enum in emc2/src/emc/motion/motion.h, called cmd_code_t. (Note that in the code, each command name starts with 'EMCMOT_', which is omitted here.)

The commands are implemented by a large switch statement in the function emcmotCommandHandler(), which is called at the servo rate. More on that function later.

There are approximately 44 commands - this list is still under construction.

ABORT

The ABORT command simply stops all motion. It can be issued at any time, and will always be accepted. It does not disable the motion controller or change any state information, it simply cancels any motion that is currently in progress.^[1]

Requirements

None. The command is always accepted and acted on immediately.

Results

In free mode, the free mode trajectory planners are disabled. That results in each joint stopping as fast as its accel (decel) limit allows. The stop is not coordinated. In teleop mode, the commanded Cartesian velocity is set to zero. I don’t know exactly what kind of stop results (coordinated, uncoordinated, etc), but will figure it out eventually. In coord mode, the coord mode trajectory planner is told to abort the current move. Again, I don’t know the exact result of this, but will document it when I figure it out.

FREE

The FREE command puts the motion controller in free mode. Free mode means that each joint is independent of all the other joints. Cartesian coordinates, poses, and kinematics are ignored when in free mode. In essence, each joint has its own simple trajectory planner, and each joint completely ignores the other joints. Some commands (like JOG) only work in free mode. Other commands, including anything that deals with Cartesian coordinates, do not work at all in free mode.

Requirements

The command handler applies no requirements to the FREE command, it will always be accepted. However, if any joint is in motion (GET_MOTION_INPOS_FLAG() == FALSE), then the command will be ignored. This behavior is controlled by code that is now located in the function 'set_operating_mode()' in control.c, that code needs to be cleaned up. I believe the command should not be silently ignored, instead the command handler should determine whether it can be executed and return an error if it cannot.

Results

If the machine is already in free mode, nothing. Otherwise, the machine is placed in free mode. Each joint’s free mode trajectory planner is initialized to the current location of the joint, but the planners are not enabled and the joints are stationary.

TELEOP

The TELEOP command places the machine in teleoperating mode. In teleop mode, movement of the machine is based on Cartesian coordinates using kinematics, rather than on individual joints as in free mode. However the trajectory planner per se is not used, instead movement is controlled by a velocity vector. Movement in teleop mode is much like jogging, except that it is done in Cartesian space instead of joint space. On a machine with trivial kinematics, there is little difference between teleop mode and free mode, and GUIs for those machines might never even issue this command. However for non-trivial machines like robots and hexapods, teleop mode is used for most user commanded jog type movements.

Requirements

The command handler will reject the TELEOP command with an error message if the kinematics cannot be activated because the one or more axes have not been homed. In addition, if any joint is in motion (GET_MOTION_INPOS_FLAG() == FALSE), then the command will be ignored (with no error message). This behavior is controlled by code that is now located in the function 'set_operating_mode()' in control.c. I believe the command should not be silently ignored, instead the command handler should determine whether it can be executed and return an error if it cannot.

Results

If the machine is already in teleop mode, nothing. Otherwise the machine is placed in teleop mode. The kinematics code is activated, interpolators are drained and flushed, and the Cartesian velocity commands are set to zero.

COORD

The COORD command places the machine in coordinated mode. In coord mode, movement of the machine is based on Cartesian coordinates using kinematics, rather than on individual joints as in free mode. In addition, the main trajectory planner is used to generate motion, based on queued LINE, CIRCLE, and/or PROBE commands. Coord mode is the mode that is used when executing a G-code program.

Requirements

The command handler will reject the COORD command with an error message if the kinematics cannot be activated because the one or more axes have not been homed. In addition, if any joint is in motion (GET_MOTION_INPOS_FLAG() == FALSE), then the command will be ignored (with no error message). This behavior is controlled by code that is now located in the function 'set_operating_mode()' in control.c. I believe the command should not be silently ignored, instead the command handler should determine whether it can be executed and return an error if it cannot.

Results

If the machine is already in coord mode, nothing. Otherwise, the machine is placed in coord mode. The kinematics code is activated, interpolators are drained and flushed, and the trajectory planner queues are empty. The trajectory planner is active and awaiting a LINE, CIRCLE, or PROBE command.