Post by jimfred on Nov 6, 2021 20:31:45 GMT
I have an intermittent problem with the Z-Axis stalling, buzzing, and losing steps. I'm thinking that the stepper controller is the cause of the problem and I'd like to run this by y'all for confirmation.
The problem seems to happen randomly independent of temperature, x y or z position and independent of load/force. When I connect the Z motor cable into the Y controller, the problem never happens. When I return the Z motor cable to its Z controller, the problem sometimes re-appears. Based on this, I think everything downstream from the green 6-pin Phoenix connector is ok, including anything mechanical (coupling etc). Also, I can turn the Z-axis motor by hand, even when powered-up, with it's holding torque which seems to rule-out mechanical jamming.
I've run tests as long as 3 hours, doing repeated 3-inch-deep drilling patterns, with no problems. Yet at other times, it'll stall, usually when travelling up, and after that, it'll stall again travelling down and then suddenly, randomly, act normal. Speed might be a factor - less likely to stall at low speeds and slightly more likely at higher speeds.
There's no correlation that I can see to temperature, x y or z position, force/torque etc except, maybe, to the value of the wood being carved (just kidding about wood value but it sometimes seems to know).
Based mostly on the cable-swap test, the problem seems to be isolated to the Z controller. It's dip switches are set at 4.9 Amps yet the X & Y dip switches are set at 2.7 Amps and this puzzles me. I would have guessed that the higher current setting, for the controller that's causing problems, would reduce problems of stalling. I'm also puzzled why the Z axis would be different - I didn't setup the machine, and I can't find a setup manual that describes this setting.
I'm guessing that the stalling/buzzing sound would be caused by [1] mechanical jamming [2] reduced drive current from the controller (maybe internal current limiting) or [3] a dropped phase due to an intermittent connection (broken wire).
Since this is intermittent I'd like to get some feedback from others. Meanwhile, I'll order a spare 5056 stepper controller and try it.
Details: MillRight Power Route (looks like this wiki.lowellmakes.com/images/Millrightcnc.png), 5056 stepper driver, about 4 years old. I can of course provide more details if it's helpful.
-Jim Fred
RP Shop Captain, Lowell Makes
The problem seems to happen randomly independent of temperature, x y or z position and independent of load/force. When I connect the Z motor cable into the Y controller, the problem never happens. When I return the Z motor cable to its Z controller, the problem sometimes re-appears. Based on this, I think everything downstream from the green 6-pin Phoenix connector is ok, including anything mechanical (coupling etc). Also, I can turn the Z-axis motor by hand, even when powered-up, with it's holding torque which seems to rule-out mechanical jamming.
I've run tests as long as 3 hours, doing repeated 3-inch-deep drilling patterns, with no problems. Yet at other times, it'll stall, usually when travelling up, and after that, it'll stall again travelling down and then suddenly, randomly, act normal. Speed might be a factor - less likely to stall at low speeds and slightly more likely at higher speeds.
There's no correlation that I can see to temperature, x y or z position, force/torque etc except, maybe, to the value of the wood being carved (just kidding about wood value but it sometimes seems to know).
Based mostly on the cable-swap test, the problem seems to be isolated to the Z controller. It's dip switches are set at 4.9 Amps yet the X & Y dip switches are set at 2.7 Amps and this puzzles me. I would have guessed that the higher current setting, for the controller that's causing problems, would reduce problems of stalling. I'm also puzzled why the Z axis would be different - I didn't setup the machine, and I can't find a setup manual that describes this setting.
I'm guessing that the stalling/buzzing sound would be caused by [1] mechanical jamming [2] reduced drive current from the controller (maybe internal current limiting) or [3] a dropped phase due to an intermittent connection (broken wire).
Since this is intermittent I'd like to get some feedback from others. Meanwhile, I'll order a spare 5056 stepper controller and try it.
Details: MillRight Power Route (looks like this wiki.lowellmakes.com/images/Millrightcnc.png), 5056 stepper driver, about 4 years old. I can of course provide more details if it's helpful.
-Jim Fred
RP Shop Captain, Lowell Makes