I'm at a loss and thought I'd see if anyone had any ideas. So here is whats happening. The y axis is sticking. So in the middle of a cut the motor binds up and throws the entire cut out of alignment. It happens at higher speeds. I had to turn the speeds down to stop it from happening.
Here is what we have tried so far:
1. lubricating the rails with white lithium grease (recommendation from the manufacturer)
2. replaced the stepper motor
3. checked the belt tension.
4. Checked wiring connections on the driver.
5. checked for error lights on the power supplies
6. Checked the shafts for loose gears and binding.
I'm trying to cut at speeds from 250-400mm/s I'm vector etching thin styrene. I have noticed several things. Some of my files have issues with very tiny line segments working their way into larger lines. I have fixed most of those and know what to look for now. I have also noticed something on the x-axis that is odd. One of the files has a lot of long straight lines. It cuts those fine but there is a small gap in some of them. maybe half an inch. The Y-axis can't cut them at all and the X-axis slams hard. Like its trying to put the brakes on and start the new line from speed 0. The y-axis just binds up and grinds to a halt.
It uses a DM422 stepper driver. I wrote down the switch settings and it looks like the Dynamic Current is set for X=5 and Y=14. both have idle current set to off. Microstep resolution is X=5 and Y=13. I'm going to double check these settings with Hurricane but they all ran off to some convention and left me hanging this week.
On a sorta related note. The Z-Axis motor gets hot. It isn't moving or doing anything but it warms up the longer the machine is on. I check the idle current setting on the driver and it is set to off as well.
I'm not really sure what to do with it and I'm on a time crunch as I have a new product I want to post for sale and I can't because the machine isn't cutting it. Any help would be great!