15mm error while cutting

Troubleshooting
1

I’ve been having issues with the lower left belt going slack on long cuts and the red error light turning on. I finally grabbed the serial output saw the following

[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.007mm Counter: 1]
[MSG:WARN: Previous error was 15.007mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.020mm Counter: 2]
[MSG:WARN: Previous error was 15.020mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.033mm Counter: 3]
[MSG:WARN: Previous error was 15.033mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.043mm Counter: 4]
[MSG:WARN: Previous error was 15.043mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.056mm Counter: 5]
[MSG:WARN: Previous error was 15.056mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.068mm Counter: 6]
[MSG:WARN: Previous error was 15.068mm]
[MSG:ERR: Emergency stop! Stopping all motors]
[MSG:WARN: The machine will not respond until turned off and back on again]
[MSG:INFO: Reset during file job at line: 995]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]

I’ve attached the GCode I used, as well. I ran this file without the router and dust collection running once to make sure it would work correctly. I’m going to try again with the router and dust running, but without the bit, to see if it happens again.

Anybody have any ideas?

This is a 4.1 Maslow with the latest V1.15 firmware.

2

One other data point is that this belt always has trouble retracting. I have to have the retraction force set to 1900 to allow it to start retracting.

3

JimB wrote:

One other data point is that this belt always has trouble retracting. I have
to have the retraction force set to 1900 to allow it to start retracting.

when an arm is that stiff, it can cause problems during calibration, which can
lead to the slack belt problem you are seeing.

you will need to take the arm apart and make it so it can move freely (sanding
the inside of the spool until it turns freely on each half of the arm)

David Lang

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4

Was worried about that. Wonder if I shot a bit of graphite lubricant in first as a trial.

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5

Probably won’t help much, too difficult to get it to where it needs to go. It tends to bind where the spool rotates internally.
Easiest way to access is to put the Z right down, undo the “caps” on the supports, then move the Z up until it clears the screw shafts, power off. Disconnect all the cables from the control board, lift off the assembly and you can loosen the screws locking on the shaft and remove the screws from the bottom to access the arms.
Sorry no easy fixes.

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6

I’m not sure I understand the specific problem I’m trying to fix. I’ve taken the router off the sled and am down to the arms. The arms seem to be spinning freely on the router itself. Is it something inside of the arms seem that I should be investigating? Do I need to take the arms apart in the two halves and do something inside of it? I can post photos if helpful.

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7

Yes. The friction is in-between the spool that holds the belt and the inside of the case that it sits in. So unscrew the parts of the arms and reduce friction inside

8

ok that makes a lot of sense. and sadly it is very very tight in there.

This is just the picture from the manual but that’s what I’m solving, right? where the inner belt spool interfaces with the hub on the housing. I cannot get these two surfaces to rotate against each other by hand at all. I’m going to sand the inside of the belt spool until it spins smoothly. Will probably take apart the other arms and do the same thing while I’m in there.

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9

JimB wrote:

ok that makes a lot of sense. and sadly it is very very tight in there.

This is just the picture from the manual but that¢s what I¢m solving, right?
where the inner belt spool interfaces with the hub on the housing. I cannot
get these two surfaces to rotate against each other by hand at all. I¢m going
to sand the inside of the belt spool until it spins smoothly. Will probably
take apart the other arms and do the same thing while I¢m in there.

Exactly. The 4.1 arms and 4.0 spools are just a little too tight, so we have to
sand them smooth (don’t forget to put some lubricant in there, silicon should be
good, when you reassemble things)

the newest spools have been made just a little larger to fit better.

when you get everything back together, see how low you can go with the current
limits and still get it to retract fully on the first try.

David Lang

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10

Good news everything is back together and rerunning calibration. I sanded all 4 arms with a Dremel sanding drum until the moved smoothly by hand. Then added some silicone lubricant for good measure.

It retracted first try at 900 and the current fitment is calculating around 1.30 in 25000. I didn’t try lower than 900, but could still. Overall I think this is fixed.

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