clough42 · blackfister · Sep 8, 2019 · Sep 8, 2019 · Nov 6, 2019 · Nov 7, 2019
diff --git a/3D Models/LaunchPad DIN Rail Mount.stl b/3D Models/LaunchPad DIN Rail Mount.stl
diff --git a/Jenkinsfile b/Jenkinsfile
@@ -6,6 +6,7 @@ pipeline {
 		stage('Import Projects') {
 			steps {
 				sh 'ccstudio -noSplash -data . -application com.ti.ccstudio.apps.projectImport -ccs.location els-f280049c || true'
+				sh 'ccstudio -noSplash -data . -application com.ti.ccstudio.apps.projectImport -ccs.location testfixture-f280049c || true'
 			}
 		}
 

diff --git a/README.md b/README.md
@@ -1,35 +1,74 @@
 # Clough42 Lathe Electronic Leadscrew Controller
 
-This is the firmware for an experimental lathe electronic leadscrew controller.  The goal is to replace the change
+This is the firmware for a lathe electronic leadscrew controller.  The goal is to replace the change
 gears or gearbox on a metalworking lathe with a stepper motor controlled electronically based on an encoder on the
 lathe spindle.  The electronic controller allows setting different virtual gear ratios for feeds and threading.
 
+![Silkscreened Control Panel](https://raw.githubusercontent.com/clough42/electronic-leadscrew/master/docs/images/CPKit.jpg)
+
+## License and Disclaimer
+
+This software is distributed under the terms of the MIT license.  Read the entire
+license statement [here](https://github.com/clough42/electronic-leadscrew/blob/master/LICENSE).
+
+**Machine tools can be dangerous.**  This is especially true of machine tools that can move by themselves
+under the control of electronics and software.  You are responsible for your own safety.  Always assume
+that something could fail and cause the machine to move unexpectedly.  Keep clear of pinch points and 
+be ready to kill the power in an emergency.
+
+## Latest Version
+
+Version 1.4.00 adds the following features and fixes:
+* Automatically detect if the ELS hits its max 100KHz step rate and fail safe
+* Change the memory map to allow more thread and feed definitions
+
+Version 1.3.01 added the following features and fixes:
+* Fix phantom control panel button presses
+* Add power button support
+* Fix integer overflow for large metric threads
+* Prevent mode and direction changes while running
+* Smooth tachometer display
+* Add support for lathes with separate feed and thread gearing
+
+[DOWNLOAD HERE](https://github.com/clough42/electronic-leadscrew/releases)
+
 ## Project Status
-Design and prototyping.
+Beta.
 
-**NOTE: This is still a work in progress and is subject to change.  Many people have expressed interest in buying parts
-and following along with the build.  That's great!  Just be aware that this hasn't been tested and refined end-to-end yet, so
-things like stepper motors, servos, drivers, display boards are likely to change as the project progresses.**
+**NOTE: This is still a work in progress and is subject to change.  Hundreds of people all over the world have purchased parts
+and built their own.  That's great!  I have had great success with mine, as have others.  Building an ELS
+for your lathe does require require basic electronics and troubleshooting skills, so keep that in mind if you decide to build one
+yourself.**
 
-## Current Concept
-The project is still in the early stages of development.  The current hardware looks like this:
+## Documentation
+For documentation, please [**VISIT THE PROJECT WIKI**](https://github.com/clough42/electronic-leadscrew/wiki).
+
+## Concept
+The project is still in active development.  The current hardware looks like this:
 * Use a TI F280049C Piccolo microcontroller on a LaunchXL prototyping board
 * Use an inexpensive SPI "LED&Key" import display and keypad for the user interface
-* Read the spindle position using a rotary encoder with a 3D-printed gear
-* Use a standard stepper motor and driver on the lathe leadscrew
+* Read the spindle position using a rotary encoder with a 3D-printed gear or belt drive
+* Use a standard stepper motor (or servo) and driver on the lathe leadscrew
 * Make as few modifications to the lathe as possible:
   * Use the original leadscrew and halfnuts without machining
   * Drive the leadscrew through the factory input shaft
   * Drive the encoder from the factory spindle gear train
   * Make it easy to restore the lathe to the original change gear configuration  
 
-The current plan is to support the following operations:
-* Multiple feeds in thousandths of an inch per revolution
-* Multiple feeds in hundredths of a millimeter per revolution
-* Multiple imperial thread pitches (in threads-per-inch)
-* Multiple metric thread pitches (in millimeters)
+The ELS firmware currently supports the following:
+* Feeds in thousandths of an inch per revolution
+* Feeds in hundredths of a millimeter per revolution
+* Imperial thread pitches (in threads-per-inch)
+* Metric thread pitches (in millimeters)
+* Imperial and Metric lead screws
+* Support for powering down the leadscrew while leaving the tachometer active
+* Tachometer averaging (stabilization)
+
+Items on the short list for future development:
+* Support for dual-shaft lathes that have different drive ratios for feeding and threading
+* Leadscrew speed limit warnings
 
-## Future Goals
+## Possible Future Goals
 While this project is starting out as a simple gearbox replacement, some features seem attractive, even for
 that simple case:
 * Threading/feeding up to a hard shoulder with automatic stop
@@ -42,7 +81,8 @@ set to almost any ratio.  The lathe will continue to operate normally, with the
 the half-nuts to control feeding and threading.
 
 ## Hardware Configuration
-If you want to get this running on your own LaunchXL-F280049C board, here are the settings you will need:
+If you want to get this running on your own LaunchXL-F280049C board, here are the settings you will need.
+See the documentation at the link above for more details.
 
 ### Physical Switches
 The LaunchXL-F280049C has a number of switches on the board to configure the GPIO and peripheral signal routing.

diff --git a/docs/images/CPKit.jpg b/docs/images/CPKit.jpg
diff --git a/docs/images/Continuity/ELSBoost-Input-Continuity-1.jpg b/docs/images/Continuity/ELSBoost-Input-Continuity-1.jpg
diff --git a/docs/images/Continuity/ELSBoost-Input-Continuity-2.jpg b/docs/images/Continuity/ELSBoost-Input-Continuity-2.jpg
diff --git a/docs/images/Continuity/ELSBoost-Output-Continuity.jpg b/docs/images/Continuity/ELSBoost-Output-Continuity.jpg
diff --git a/docs/images/Continuity/ELSBoost-Power-Continuity.jpg b/docs/images/Continuity/ELSBoost-Power-Continuity.jpg
diff --git a/docs/images/Continuity/LEDandKEY-Continuity.jpg b/docs/images/Continuity/LEDandKEY-Continuity.jpg
diff --git a/docs/images/Driver.jpg b/docs/images/Driver.jpg
diff --git a/docs/images/ELSBoost.jpg b/docs/images/ELSBoost.jpg
diff --git a/docs/images/EasyServoMotor.jpg b/docs/images/EasyServoMotor.jpg
diff --git a/docs/images/Encoder.jpg b/docs/images/Encoder.jpg
diff --git a/docs/images/Icons200/CPKit.jpg b/docs/images/Icons200/CPKit.jpg
diff --git a/docs/images/Icons200/Driver.jpg b/docs/images/Icons200/Driver.jpg
diff --git a/docs/images/Icons200/ELSBoost.jpg b/docs/images/Icons200/ELSBoost.jpg
diff --git a/docs/images/Icons200/EasyServoMotor.jpg b/docs/images/Icons200/EasyServoMotor.jpg
diff --git a/docs/images/Icons200/Encoder.jpg b/docs/images/Icons200/Encoder.jpg
diff --git a/docs/images/Icons200/LEDandKEY.jpg b/docs/images/Icons200/LEDandKEY.jpg
diff --git a/docs/images/Icons200/LaunchPad.jpg b/docs/images/Icons200/LaunchPad.jpg
diff --git a/docs/images/Icons200/PowerSupply.jpg b/docs/images/Icons200/PowerSupply.jpg
diff --git a/docs/images/Icons200/ServoMotor.jpg b/docs/images/Icons200/ServoMotor.jpg
diff --git a/docs/images/Icons200/WallWart.jpg b/docs/images/Icons200/WallWart.jpg
diff --git a/docs/images/IntegratedServoWiringDiagram.jpg b/docs/images/IntegratedServoWiringDiagram.jpg
diff --git a/docs/images/JumpersAndSwitches.JPG b/docs/images/JumpersAndSwitches.JPG
diff --git a/docs/images/LEDandKEY.jpg b/docs/images/LEDandKEY.jpg
diff --git a/docs/images/LaunchPad.jpg b/docs/images/LaunchPad.jpg
diff --git a/docs/images/PowerSupply.jpg b/docs/images/PowerSupply.jpg
diff --git a/docs/images/ServoMotor.jpg b/docs/images/ServoMotor.jpg
diff --git a/docs/images/WallWart.jpg b/docs/images/WallWart.jpg
diff --git a/docs/images/WiringDiagram.JPG b/docs/images/WiringDiagram.JPG
diff --git a/docs/images/thumbnails/ELS - Part 1 - Proof of Concept.jpg b/docs/images/thumbnails/ELS - Part 1 - Proof of Concept.jpg
diff --git a/docs/images/thumbnails/ELS - Part 10 - Programming the Microcontroller.jpg b/docs/images/thumbnails/ELS - Part 10 - Programming the Microcontroller.jpg
diff --git a/docs/images/thumbnails/ELS - Part 2 - Virtual Gear Calculations.jpg b/docs/images/thumbnails/ELS - Part 2 - Virtual Gear Calculations.jpg
diff --git a/docs/images/thumbnails/ELS - Part 3 - Display and Debugging.jpg b/docs/images/thumbnails/ELS - Part 3 - Display and Debugging.jpg
diff --git a/docs/images/thumbnails/ELS - Part 4 - Steppers and Servos and Drivers.jpg b/docs/images/thumbnails/ELS - Part 4 - Steppers and Servos and Drivers.jpg
diff --git a/docs/images/thumbnails/ELS - Part 5 - Motor and Encoder Mounting.jpg b/docs/images/thumbnails/ELS - Part 5 - Motor and Encoder Mounting.jpg
diff --git a/docs/images/thumbnails/ELS - Part 9 - Machining the Control Panel.jpg b/docs/images/thumbnails/ELS - Part 9 - Machining the Control Panel.jpg
diff --git a/els-f280049c/28004x_generic_ram_lnk.cmd b/els-f280049c/28004x_generic_ram_lnk.cmd
@@ -104,9 +104,9 @@ SECTIONS
    .reset           : > RESET,     PAGE = 0, TYPE = DSECT /* not used, */
 
    .stack           : > RAMM1,     PAGE = 1
-   .ebss            : > RAMLS5,    PAGE = 1
-   .econst          : > RAMLS5,    PAGE = 1
-   .esysmem         : > RAMLS5,    PAGE = 1
+   .ebss            : > RAMLS5|RAMLS6,    PAGE = 1
+   .econst          : >> RAMLS5|RAMLS6,    PAGE = 1
+   .esysmem         : > RAMLS5|RAMLS6,    PAGE = 1
 
    ramgs0           : > RAMGS0,    PAGE = 1
    ramgs1           : > RAMGS1,    PAGE = 1  

diff --git a/els-f280049c/Configuration.h b/els-f280049c/Configuration.h
@@ -55,12 +55,23 @@
 // Define the number of steps and microsteps for your stepper motor, the pin
 // polarity of the driver, and whether to use additional features, like servo
 // alarm feedback.
+//
+// NOTE: If you are using a servo drive with something other than a 1:1 drive
+// ratio, you can use the STEPPER_MICROSTEPS to compensate.  For example, if you
+// have a servo configured for 1000 steps/revolution and it drives the leadscrew
+// through a 3:1 reduction, you can set STEPPER_RESOLUTION to 1000 and
+// STEPPER_MICROSTEPS to 3.
 //================================================================================
 
 // Steps and microsteps
 #define STEPPER_MICROSTEPS 8
 #define STEPPER_RESOLUTION 200
 
+// Separate step and microstep settings for feed rates.  Redefine these if your
+// lathe has a separate feed drive train with a different ratio.
+#define STEPPER_MICROSTEPS_FEED STEPPER_MICROSTEPS
+#define STEPPER_RESOLUTION_FEED STEPPER_RESOLUTION
+
 // Step, direction and enable pins are normally active-high
 // #define INVERT_STEP_PIN true
 // #define INVERT_DIRECTION_PIN true
@@ -78,9 +89,19 @@
 //
 // Define the type of encoder you are using on the spindle.  The firmware assumes
 // the encoder is turning at a 1:1 ratio with the spindle.
+//
+// NOTE: the firmware is concerned with the quadrature edge count, which is
+// four times the number of pulses.  For example, if you have a 1024 P/R
+// encoder, you need to enter 4096 here.
 //================================================================================
+
+// Encoder resolution (counts per revolution)
 #define ENCODER_RESOLUTION 4096
 
+// Which encoder input to use
+#define ENCODER_USE_EQEP1
+//#define ENCODER_USE_EQEP2
+
 
 
 
@@ -97,6 +118,47 @@
 
 
 
+//================================================================================
+//                                HARDWARE
+//
+// Define which hardware you're using:
+//
+//  1 - LaunchXL F280049C with ELS BoostXL v1
+//  2 - LaunchXL F280049C with ELS BoostXL v2
+//================================================================================
+
+// See hardware version table above
+#define HARDWARE_VERSION 2
+
+
+
+
+//================================================================================
+//                                FEATURES
+//
+// Additional features that can be enabled for your configuration.
+//================================================================================
+
+// Ignore all key presses when the machine is running.  Normally, only the mode
+// and direction keys are ignored.
+//#define IGNORE_ALL_KEYS_WHEN_RUNNING
+
+
+
+
+//================================================================================
+//                              VALIDATION/TRIP
+//
+// Validation thresholds and automatic trip behavior.
+//================================================================================
+
+// Maximum number of buffered steps
+// The ELS can only output steps at approximately 100KHz.  If you ask the ELS to
+// output steps faster than this, it will get behind and will stop automatically
+// when the buffered step count exceeds this value.
+#define MAX_BUFFERED_STEPS 100
+
+
 //================================================================================
 //                               CPU / TIMING
 //
@@ -112,13 +174,11 @@
 #define UI_REFRESH_RATE_HZ 100
 
 // RPM recalculation rate, in Hz
-#define RPM_CALC_RATE_HZ 10
+#define RPM_CALC_RATE_HZ 2
 
 // Microprocessor system clock
 #define CPU_CLOCK_MHZ 100
 #define CPU_CLOCK_HZ (CPU_CLOCK_MHZ * 1000000)
 
 
-
-
 #endif // __CONFIGURATION_H
diff --git a/els-f280049c/ControlPanel.cpp b/els-f280049c/ControlPanel.cpp
@@ -27,10 +27,13 @@
 #include "ControlPanel.h"
 
 // Time delay to allow CS (STB) line to reach high state and be registered
-#define CS_RISE_TIME_US 5
+#define CS_RISE_TIME_US 10
 
 // Time delay after sending read command, before clocking in data
-#define DELAY_BEFORE_READING_US 1
+#define DELAY_BEFORE_READING_US 3
+
+// Number of times a key state must be read consecutively to be considered stable
+#define MIN_CONSECUTIVE_READS 3
 
 
 // Lower the TM1638 CS (STB) line
@@ -47,6 +50,8 @@ ControlPanel :: ControlPanel(SPIBus *spiBus)
     this->value = NULL;
     this->leds.all = 0;
     this->keys.all = 0;
+    this->stableKeys.all = 0;
+    this->stableCount = 0;
     this->message = NULL;
     this->brightness = 3;
 }
@@ -236,13 +241,53 @@ KEY_REG ControlPanel :: getKeys()
     configureSpiBus();
 
     newKeys = readKeys();
-    if( newKeys.all != this->keys.all ) {
+    if( isValidKeyState(newKeys) && isStable(newKeys) && newKeys.all != this->keys.all ) {
+        KEY_REG previousKeys = this->keys; // remember the previous stable value
         this->keys = newKeys;
-        return newKeys;
+
+        if( previousKeys.all == 0 ) {     // only act if the previous stable value was no keys pressed
+            return newKeys;
+        }
     }
     return noKeys;
 }
 
+bool ControlPanel :: isValidKeyState(KEY_REG testKeys) {
+    // filter out any states with multiple keys pressed (bad communication filter)
+    switch(testKeys.all) {
+    case 0:
+    case 1 << 0:
+    case 1 << 2:
+    case 1 << 3:
+    case 1 << 4:
+    case 1 << 5:
+    case 1 << 6:
+    case 1 << 7:
+        return true;
+    }
+
+    return false;
+}
+
+
+bool ControlPanel :: isStable(KEY_REG testKeys) {
+    // don't trust any read key state until we've seen it multiple times consecutively (noise filter)
+    if( testKeys.all != stableKeys.all )
+    {
+        this->stableKeys = testKeys;
+        this->stableCount = 1;
+    }
+    else
+    {
+        if( this->stableCount < MIN_CONSECUTIVE_READS )
+        {
+            this->stableCount++;
+        }
+    }
+
+    return this->stableCount >= MIN_CONSECUTIVE_READS;
+}
+
 void ControlPanel :: setMessage( const Uint16 *message )
 {
     this->message = message;

diff --git a/els-f280049c/ControlPanel.h b/els-f280049c/ControlPanel.h
@@ -137,6 +137,10 @@ class ControlPanel
     // current key states
     KEY_REG keys;
 
+    // number of times current key state has been seen
+    KEY_REG stableKeys;
+    Uint16 stableCount;
+
     // current override message, or NULL if none
     const Uint16 *message;
 
@@ -159,6 +163,8 @@ class ControlPanel
     Uint16 reverse_byte(Uint16 x);
     void initSpi();
     void configureSpiBus(void);
+    bool isValidKeyState(KEY_REG);
+    bool isStable(KEY_REG);
 
 public:
     ControlPanel(SPIBus *spiBus);

diff --git a/els-f280049c/Core.cpp b/els-f280049c/Core.cpp
@@ -40,6 +40,8 @@ Core :: Core( Encoder *encoder, StepperDrive *stepperDrive )
     this->previousSpindlePosition = 0;
     this->previousFeedDirection = 0;
     this->previousFeed = NULL;
+
+    this->powerOn = true; // default to power on
 }
 
 void Core :: setReverse(bool reverse)
@@ -54,6 +56,11 @@ void Core :: setReverse(bool reverse)
     }
 }
 
+void Core :: setPowerOn(bool powerOn)
+{
+    this->powerOn = powerOn;
+    this->stepperDrive->setEnabled(powerOn);
+}
 
 
 

diff --git a/els-f280049c/Core.h b/els-f280049c/Core.h
@@ -54,6 +54,8 @@ class Core
 
     int32 feedRatio(Uint32 count);
 
+    bool powerOn;
+
 public:
     Core( Encoder *encoder, StepperDrive *stepperDrive );
 
@@ -62,6 +64,9 @@ class Core
     Uint16 getRPM(void);
     bool isAlarm();
 
+    bool isPowerOn();
+    void setPowerOn(bool);
+
     void ISR( void );
 };
 
@@ -84,6 +89,11 @@ inline bool Core :: isAlarm()
     return this->stepperDrive->isAlarm();
 }
 
+inline bool Core :: isPowerOn()
+{
+    return this->powerOn;
+}
+
 inline int32 Core :: feedRatio(Uint32 count)
 {
 #ifdef USE_FLOATING_POINT