I have a DIY 48x96 router table. I drive all axis with 570in/oz steppers with 2 on the X axis. I set my max speeds and max acceleration numbers with the following procedure.
I set the acceleration to a low number then set the max rate to some number and ran that axis back and forth far enough for the axis to get up to max speed like 10 times. I ramped up the speed and did it again. I kept doing this until I got the axis to stall then I reduced that speed by 20%. I then set to ramping up the acceleration in a likewize manner until it stalled again then reduced that acceleration by 20% again.
Doing this I have had no issues with my Y or Z axis but my X will randomly stall when in a program.
My max speed on the X axis is 800 IPM not cutting. Today I was happily running a table surfacing program at 400 IPM with a 2 inch diameter surfacing bit. I made several complete dry runs with no issues and made one complete run with the spindle on with no issues. When going for another run at .02 inches deeper the X axis stalled after going up and back twice just after it made the turn to start cutting again. I reran the program and it stalled in exactly the same place. I went to manual control using UGS and the axis moved at 800IPM at that point with no problem. I ran the program again and the axis stalled at the other end of the table when the bit was in AIR and not really cutting at all.
At that point I discovered I had a broken limit switch so I took some time to replace that. I then ran 2 cycles of the same program cutting air with no issue.
I am at a loss. What can cause RANDOM stalls of an axis running at half its max speed and according to the power curve at 400 IPM it should be at peak power.
I did not feel the motors when they stalled. Can over heating cause a problem?? If so, how hot is to hot?
What else can cause random stalls.
Getting real frustrated. I fixed a problem yesterday where I accidentally had one of the motor wires shield touching one pin on the connector. It was making a lot of noise. Had stalling problems before fixing that so I was hoping that was it but no joy.
BTW I am running an Arduino/GRBL set up. All Automation Technologies PS drives and motors.
Help
Thanks