Loosing steps in my X.

Gary, I’m not sure what you’re talking about but I’m assuming Deepgroove1 matched the resistor to the motors since it was a package.


Jim & Royce, I sent you the DWG, BBCD, and NC files for your amusement. I don’t think it's program related because the severity of it changes each time I run it. I reduced my rapid move from 40 to 20 and it seemed to improve. I then reduced it to 10 but the result looked worse? Like Alton suggested, could things be heating up and giving my control box heat stroke?
 
DanO said:
Gary, I’m not sure what you’re talking about but I’m assuming Deepgroove1 matched the resistor to the motors since it was a package.


Jim & Royce, I sent you the DWG, BBCD, and NC files for your amusement. I don’t think it's program related because the severity of it changes each time I run it. I reduced my rapid move from 40 to 20 and it seemed to improve. I then reduced it to 10 but the result looked worse? Like Alton suggested, could things be heating up and giving my control box heat stroke?
Click to expand...

Dano, I didn't get the files for some reason however Royce sent them to me. I agree that the G-code program looks good in Mach 3. If you suspect heat as an issue then try putting a fan on the G540 back side. I believe if you wanted there is a fan chiller unit out there for that. Also, could be mechanical binding, motor connection, or motor. You can swap stepper drives by moving X and Y motor power cables. Then change the settings in Mach's motor outputs step and direction pins. At this point the program should run in the normal direction. Let me know if this doesn't make sense. Now if you suspect binding, remove the motor or the leads screw from the axis. Move the X axis by hand slow and then faster.

Good luck,
Jim.
 
Thanks for looking. I'm confident that I have no binding, or slipping for that matter, since I've already researched that possibility. I'll open things up this weekend a get some air flow to see if that makes a difference. I'd play with it tonight but I have to do a stupid past time called shooting pool.
 
DanO

load a copy of your code in a editor and change all of your G00 to G01 moves and run a part.this will help you proof the code and remove the rapids of the machine at the same time.

bill
 
Dano,

I agree with Jim, and I don't think your issue is with your code.

Over the years, I have every kind of issue you can imagine. I've even had the bearings on the motor go out and cause it to miss steps!

I don't really think you have a heat issue as it's only causing an issue in one axis.

You mentioned that you slowed the rapids down, but did you slow down the accelerations? I can make any of my machines miss steps with really slow speeds if I have the accels too high. As has been said, you can edit your code in Mach3, and replace all the G00 with G01. You'll need to give it a speed, then you'll know if it just can't handle the rapids.

As for the mechanicals, I usually start by removing the axis nut from the axis. That way I can slide the axis by hand and make sure I don't have any binding. I've had dust get into the linear bearings and cause them to be really tight. A little lube fixes them, but then they attract more dust. If it slides easy, then I hold the nut and try to rotate the screw by hand. Keep the stepper in place, just turn off your controller so it isn't holding. You should be able to feel any significant resistance there. Then check for loose set screws, broken couplers etc. If you think it's in the individual axis on the controller, then swap it to a different axis on the board. It's an easy pin out change in Mach3 just to check it and see. You can swap motors, or motors and cables.


When you run these machines 8 hours a day like we do, they can develop all sorts of unexpected problems. Just be logical, and be diligent and you will find it. Remember, after you find it, it always seems real simple.


Royce
 
Well I decreased my acceleration and guess what, no more skipping. Thanks for everyone’s input, I was really chasing my tail. I stepped out of the box and doubled my feed rates and I’m cutting faster and more precise than ever. Before I use any of my previous programs I’ll play with my fits since I’m thinking this problem may have effected even my simple darts with me unaware.

Really, the postings and pm’s turned a possible nightmare into a simple solution. I can’t contribute much in return but I will try when I can.
 
DanO said:
Well I decreased my acceleration and guess what, no more skipping. Thanks for everyone’s input, I was really chasing my tail. I stepped out of the box and doubled my feed rates and I’m cutting faster and more precise than ever. Before I use any of my previous programs I’ll play with my fits since I’m thinking this problem may have effected even my simple darts with me unaware.

Really, the postings and pm’s turned a possible nightmare into a simple solution. I can’t contribute much in return but I will try when I can.
Click to expand...

You already have, by replying to the thread and reporting your solution.
All the little pieces make up the trouble shooting guide.
Thanks for the reporting back.
Neil
 
DanO said:
Well I decreased my acceleration and guess what, no more skipping. Thanks for everyone’s input, I was really chasing my tail. I stepped out of the box and doubled my feed rates and I’m cutting faster and more precise than ever. Before I use any of my previous programs I’ll play with my fits since I’m thinking this problem may have effected even my simple darts with me unaware.

Really, the postings and pm’s turned a possible nightmare into a simple solution. I can’t contribute much in return but I will try when I can.
Click to expand...


Dano, what do you have acc/dec set too and what is your velocity set at? Setting the acc/dec too low has some interesting side effects.

Jim.
 
Mc2 said:
Dano, what do you have acc/dec set too and what is your velocity set at? Setting the acc/dec too low has some interesting side effects.

Jim.
Click to expand...

My velocity is set to 10 & my acceleration is 0.5. Even though I slowed down the Mach3 settings, I cut about 1/3 off my program time by taking Royce’s advice by increasing my cutting feed. I’m only at 8 but them dang cutters aren’t cheap. I'm screamin mannn. OK so now I’m walking instead of crawling.
 
DanO said:
My velocity is set to 10 & my acceleration is 0.5. Even though I slowed down the Mach3 settings, I cut about 1/3 off my program time by taking Royce’s advice by increasing my cutting feed. I’m only at 8 but them dang cutters aren’t cheap. I'm screamin mannn. OK so now I’m walking instead of crawling.
Click to expand...

Dano, I know Royce was talking about cutting faster than that. What is the pitch of your lead screws? Seems like your settings are way too low. If your missing steps at other settings, What where they set at originally? Something is still not set correctly. How long would you expect it to take to pocket out that inlay?

Jim.
 
My Kerk lead screws are Ø3/4-16 pitch. The original pocket I sent you took me 40+ minutes to cut.

I made more improvements yesterday. I bumped my Mach3 settings up a bit and increased my feed rates some more. My rough feed rate is now 12 inch/min and finish feed is 4. My cut depth is .017 per pass. I’m still only gong 2/3 the speed that Royce recommended. The roughing didn’t miss a lick but the finish pass gives me that hair raising growl in the corners. I may back off. I cut the pocket in 14.58, the eyes in 4.10 and the part in 3.07. I changed the design of the eyes, nose and forehead from the first drawing but it’s probably not relative to the cut time.

I’m using an Ø.031 cutter. On both pockets my program cutter size is Ø.031. The program cutter size on the right part is Ø.028. The program cutter size on the left part is Ø.031, line to line with the pocket.
 

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Dano, I wondered why you had your velocity set so low. 16 threads per inch and 3/4 leads screw explains it. Sounds like you got everything worked out.

good luck.
Jim.
 
Finally finished what I started. Funny. I look back at my original posted pic and it looks more like a bald guy with a bad comb over. :D
 

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