I’m going a bit mad trying to figure out what to try next with an interrmittent problem. I am hoping someone can suggest what to try next.
Ok, I know this is a TLDR, but I tried to get as much info out ther first time.
My setup runs perfectly for a day at 2400mm/min, then the next day will only get to 600mm/min before the steppers stall half way through a traverse. When running at 2400 it is very smooth and quiet with no vibration in the lead screws and very little noise from the motors. Acceleration has been tested between 25 and 100 mm/sec^2 with very little change in the power rail voltage.
I also get an occasional stall even at 600mm/min which tends to ruin the workpiece I live in South Africa and our mains power regulation problems are well known. This may be a contributing factor.
I’ve checked the power rails with a scope on two separate power supplies that should both be good enough to run this setup - and they do sometimes - details below.
I’ve changed between 3200 anad 6400 steps/rev and adjusted current within the motors specifications with very lttle or no change in the problem. Should I go all the way to 400/rev?
What I cant understand is that it is intermittent, on the days it works, it can work for hours on end at 2000mm/min cutting. I use a new Makita 3600B router, it does not matter if the spindle is running or stopped, on or off the speed controller, the noise filters should be Ok. Maybe a Balun?
It does not appear to be linked to heat since it will happen first thing in the morning, or after a few hours. The lead screws are clean and lightly oiled.
I am running GRBL on an ESP32 which has its own Meanwell 5V 4A supply.
I have routed all high power leads away from the control lines
I have twisted all low power leads ( end stops, estop, probe and GRBL to stepper controller)
All axes are driven by 12mm diam by 3mm pitch lead screws ( RS components
Power wires are 1.2mm braided (About as thick as I can safely get into the Phoenix connectors)
Options I am considering
- Beef up the smoothing on the power supplies - extra caps and inductors
- Put a wave trap in the mains supply
- Change the GRBL controller board and software
- Change signal wires to UTP or STP
- Change stepper drives (There are already 2 makes, used within their limits (3.5A, 8A)
- Use the 1/2 winding taps on the stepper motors i.e Red/White and Green/Yellow
- SMPS (The best I have will only give 24V 2A)
- Should I be looking elsewhere with the scope?
I am open to other suggestions.
Power supply 1
Torroid rated 250VA 25A Full bridge diode , 2 by 15000uF caps in parallel, 0.1uf noise filters
Gives 32V on no load drops to 28V with 2V ripple at full load
DQ860MA on Y rated 24V-80V
I could not see anything on the scope below 28V even during (de)acceleration.
Power Supply 2
Torroid transformer rated 500VA gives 53V no load 25A Full bridge diode
22000uF capacitor.
Autotransformer (rated 220V 8A) to bring voltage down to 40V. XZ drivers rated to 45V.
Drops to 38V on full load 2V ripple
This was tried in order to check that the stepper controlers were not going under voltage.
It should also rule out the possibility of back EMF being the problem.
X and Z Axes
Wantai 57BYGH420B 3.6V 2A using full windings (Red/Blue and Green/Black) phases
Fulling 3.5A controller rated 4.2A peak 3.0 amps RMS
set to 3.31A Peak, 2.86A RMS 1/2 current on hold
(Power settings tried at 2.84, 2.37, 1.91, 1.46, 1.0A Pk and 2.03, 1.69, 1.36, 1.04, 0.71A RMS)
There are two independent controllers and two motors on Z axis.
Controllers rated 18 to 45volts and 3.5A
Y Axis
Wantai 57BYGH115-003 3A
Waintai DQ860MA controller rated 24-80V and 8APk, 4.0 RMS.
controller set to 6400 steps/rev, 3.5A peak, 2.5A RMS and 1/2 current on hold
I’ve also tried other current settings (2.0, 3.5, 4.2,4.7 pk 2.0, 2.5, 3.0, 3.5RMS)