This afternoon I did 10 test runs to see if I could get some more test data on the 15mm error. The test runs all used the same small test file on the same board area. a small job with some pocket shapes and a few profile cuts around a 10 x 20 cm area.
I did the first 2 testruns with the router switched off and no dust collection: these went fine.
Next I did 2 runs with the router turned on, but not cutting into the material: also fine.
Next 2 runs with the router turned off and dust collection on (standard Festool hose): also fine.
Next 2 runs with both the router and the dust collection on, still not cutting into the material: fine again.
Finally I did 2 actual runs cutting into the material (18 mm MDF) with dust collection on: both runs crashed after cutting for some 5 minutes, but not at the same point.
first fail log:
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[MSG:WARN: Encoder read failure on Bottom Left]
[MSG:WARN: Bad connection on Bottom Left encoder, failed to read 2 times in the last second]
[MSG:INFO: Reset during file job at line: 124]
[MSG:ERR: Emergency stop. Update function not being called enough.1002ms since last call]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -16.467mm Counter: 1]
[MSG:WARN: Previous error was -16.467mm]
[MSG:ERR: Emergency stop. Update function not being called enough.1002ms since last call]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -15.943mm Counter: 2]
[MSG:WARN: Previous error was -15.943mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -15.935mm Counter: 3]
[MSG:WARN: Previous error was -15.935mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -15.935mm Counter: 4]
[MSG:WARN: Previous error was -15.935mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -15.935mm Counter: 5]
[MSG:WARN: Previous error was -15.935mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -15.927mm Counter: 6]
[MSG:WARN: Previous error was -15.927mm]
[MSG:ERR: Emergency stop! Stopping all motors]
[MSG:WARN: The machine will not respond until turned off and back on again]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
second fail log:
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -18.179mm Counter: 1]
[MSG:WARN: Previous error was -18.179mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -18.187mm Counter: 2]
[MSG:WARN: Previous error was -18.187mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -18.202mm Counter: 3]
[MSG:WARN: Previous error was -18.202mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -18.202mm Counter: 4]
[MSG:WARN: Previous error was -18.202mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -18.210mm Counter: 5]
[MSG:WARN: Previous error was -18.210mm]
[GC:G1 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G1 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G1 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G1 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G1 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[GC:G2 G54 G17 G21 G90 G94 M5 M9 T0 F500 S0]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -22.394mm Counter: 1]
[MSG:WARN: Previous error was -22.394mm]
[MSG:INFO: Reset during file job at line: 160]
[MSG:ERR: Emergency stop. Update function not being called enough.1003ms since last call]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -21.894mm Counter: 2]
[MSG:WARN: Previous error was -21.894mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -21.886mm Counter: 3]
[MSG:WARN: Previous error was -21.886mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -21.886mm Counter: 4]
[MSG:WARN: Previous error was -21.886mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -21.879mm Counter: 5]
[MSG:WARN: Previous error was -21.879mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is -21.871mm Counter: 6]
[MSG:WARN: Previous error was -21.871mm]
[MSG:ERR: Emergency stop! Stopping all motors]
[MSG:WARN: The machine will not respond until turned off and back on again]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
Conclusions ???
The router produces more EMF when actually cutting?
Static buildup in the dust collection hose is higher when actually cutting?
Encoders are more sensitive when actually cutting?
BTW: I do have a ferrite clamp around the Maslow power cable.
BTW2: when running the non-cutting tests, I sometimes grabbed the sled with my hands to simulate cutting resistance.