This is my second/back to back E-stop trying to initially run a g-code sample (router off). This happens when the sled is moving to the right (opposite the error axis) on the work surface. It seems to happen in the same spot on the work surface…the point at significant belt angle diversion from the tensioning/non-tensioning side of the sled.
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.037mm Counter: 1]
[MSG:WARN: Previous error was 15.037mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.025mm Counter: 1]
[MSG:WARN: Previous error was 15.025mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.075mm Counter: 2]
[MSG:WARN: Previous error was 15.075mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.127mm Counter: 3]
[MSG:WARN: Previous error was 15.127mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.014mm Counter: 4]
[MSG:WARN: Previous error was 15.014mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.074mm Counter: 5]
[MSG:WARN: Previous error was 15.074mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.116mm Counter: 6]
[MSG:WARN: Previous error was 15.116mm]
[MSG:ERR: Emergency stop! Stopping all motors]
Hi Bar,
had the same problem with one of my cuts today, When the M4 was moving back to the beginning of the cut after completing a 1.5mm cut in MDF, it failed with the following: [MSG:WARN: Position error on Bottom Right axis exceeded 15mm while running. Error is 15.132mm Counter: 6] [MSG:WARN: Previous error was 15.132mm] [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: 659] [MSG:ERR: Position error > 15mm while running. E-Stop triggered.] Stop Maslow and Gcode
Maslow stopped but the code kept running and when it got to the start of the next segment it lowered the Z axis (with the Router still running) into the job.
I reset everything (except the Z axis) and restarted the job. It failed again in nearly the same spot while it was returning to the start to do the deeper cut. M4 again lowered the Z axis and the difference was about 25mm between the resultant holes on the same line between start and end points.
Cutting power to the M4 in this circumstance results it not knowing the Z depth so the second attempt also cut through sacrificial layer below it. Before running again, check Z setting.
At this point I raised and reset the Z axis and turned off the router.
I then modified the code so M4 went left and then up instead of diagonally.
Code Segments around line 627 of 2.nc (62.0 KB) 2b.nc (62.0 KB)
Update to previous reply
I lifted the Z axis and reset the z axis 10mm higher (so bit wouldn’t engage) and reran the original (failing) file 2.nc. It didn’t fail but I got error messages. Not sure when error occurred, was watching M4 not the screen. Log file attached. Hope this helps to identify this bug.
Is it possible to print the current file’s line number when printing Warn Message? Maslow-serial (31).log (2.9 KB)
Differences:
Z 10mm higher
Router not running
What I have learned:
With 240V DeWalt Router running on speed 1 and using a Maslow 1/4", 2 flute up cutting bit, It can cut at least 8mm deep into the MDF backing without hesitating! Wished I hadn’t learnt this that way!!
Check the Belts First
Bottom Left Belt Tension: Too loose means slipping, too tight means binding. Pay extra attention when the sled reaches the error point - does tension suddenly become uneven?
Belt Path: Make sure nothing’s stuck in the belt path, and it’s not twisted. Smooth movement is key.
Encoder Issues?
Bottom Left Encoder Wheel: Is it aligned properly? Are the magnets intact? Clipped encoders must be perfectly aligned with the sensor - even a slight misalignment can cause chaos.
Quick Test: Swap the Bottom Left encoder/motor with another axis. If the problem moves with the hardware, replace the faulty part.
Recalibrate Properly
Do a fresh manual calibration - don’t rely on old settings. Use a calibration square to check if the machine is actually square. A warped 8x10 wood frame can mess things up.
Don’t Ignore Hardware Basics
Clean and lube rails/wheels: Dirt or friction can cause binding.
Check wiring: Loose motor/encoder cables mean missed steps.
Bonus Checks
Update Firmware: Check if FW 1.05 has known bugs (search forums for “position error” issues).
Adjust Motor Current: Slightly increase Bottom Left motor current (but don’t overdo it).
Testing Tips:
Run the G-code without the router at slow speed to see where it binds.
Note the exact coordinates where it fails and inspect that area closely.
If anyone else has faced this, share your fixes! Let’s get this sorted.
Initially generated the code using the excellent KrabzCAM then used a text editor (Notepad++) to change code to lift router and move to next cutting position using G0 codes. This resulted in a diagonal movement back to the start. On the diagonal move, the error occurred, the motors stopped but the code kept running on the M4. When the code got to the point where it lowered the router, it drilled a hole where it had stopped on the job.
To fix the code I added another line which moved the router sideways then up, avoiding the diagonal.
In all the reports I have seen it has always failed when moving diagonally, Is this correct?
I wonder if small errors are accumulating until it reaches a threshold. It might be worthwhile printing out position error data to see if it is a steady increase or sudden onset.
It’s possible that we’re letting the machine move diagonally faster than it’s actually capable of moving. That is the slowest physical direction of movement and maybe for some frame size and some direction of movement it can’t keep up.
Really instead of saying that the maximum movement speed is 3,000 mm/min we should be computing the max in each direction at each location for the given frame size.
Set diagonal movement speed to 1000 (G1 x154.04791319 y1190.01358752 f1000)
Did not report error, changed it to F2000, still no error
This was without router and Z zero set to 10 above work (Max depth of cut -3mm)
has anyone found a solution. got half way through my first ever cut and this is happeneing. treid moving the item im cutting on the board and still not working. any help ?
Update observations.
I have made several cuts yesterday and finally had a reoccurrence of 15mm error.
I noted just prior to the failure loud clicks were coming from the M4 indicative of a belt slipping or jumping
I have noticed that I have had to increase the force needed to retract in order to get the 2 left belts to retract. Initially after the upgrade only needed 900 to retract, as I have used the machine this has incrementally needed to increase from 900, 1100, 1200 and then 1300, for the 2 belts on the left.
I have pulled the machine down and checked each belt. I had a lot of difficulty manually turning the 2 belts on the left. After cleaning the sawdust out of them and lubricating with locksmiths dry lubricant (carbon) they now turn easily. I also checked the two right hand belts, which were a lot cleaner and still moved easily before cleaning and lubricating. I note the build up of dust is more pronounced on the left side of the M4 which is consistent with the direction of rotation of the router.
It appears the problem I experienced is related to the increased resistance to rotation of the belt spool due to sawdust.
I won’t get a chance to check anything more before Monday Australian time.
After cleaning and reassembly, I set the Retract value to 700 & successfully Retracted, Extended the belts right out and Retracted again. I then reset M4 zero stop.
I then ran the failed job without a bit in the router without any errors, modified the nc code manually to get to the point where it failed before, and finished the cut.
See cnking’s entry above, he gives a pretty good summary of steps to correct. I think the sawdust causes binding, so my problem was probably different than yours.
