Hi guys,
I recently swapped out an axis on my machine to a new axis, leaving everything else the same. Only thing that changed was the frame and lead screw, same motor, same box, same wiring, same PC, same everything. The machine had 2000+ hours of runtime on it, and made maybe 5 mistakes that entire time. Currently I cannot run it for more than 20 minutes without the new axis stalling. I've been troubleshooting for 3 days, here's a little background:
Full size PC, not a laptop, running to a Campbell Designs breakout board, wired to Gecko 202 drivers, then steppers. Power supply is plenty big, no wiring was changed from the original setup, only the mechanical axis.
The only axis that is missing steps is the X axis. On this particular machine, the X axis moves vertically, photo attached. This axis has a 640 oz. stepper on it. The piece that was swapped out was a TKH rail, I replaced it with a K2 unit as pictured. After tuning it and getting the new axis running just right, I was able to jog it at 100, with an acceleration anywhere from 5 to 20. When it came time to actually start carving with the machine, I tuned it down to a feed rate of 60, acceleration of 10. After 20 minutes or so it jumps roughly 1" up or down, then continues carving in the wrong place.
I reduced the feed rate several times, and anywhere from a half hour to an hour into a run the X locks and jumps an inch or so, then keeps going. I finally tried with with acceleration set at 1, feed rate of 20, and it did the same thing after about an hour.
It seems to stall and jump an inch or so no matter the speed or acceleration settings. Neither of the other axis ever miss a step. The code hasn't changed, running the same files I've been running for years.
With everything turned off, the lead screw moves easily by hand, there is no binding through the whole range of motion. Everything is smooth as silk.
I don't believe it could be a lead-screw resonance problem, because even at the slowest speeds possible it still jumped. Currently I think the motor or gecko driver could have a physical problem, but would appreciate some input...I'm fairly stumped and getting a little more behind each day.