6050 Stopping Intermitently

[lesterb]

We have a 6050 CNC router and are having problems with it stopping intermitently. Part way through a job it will stop moving but the cutter is still spinning and Mach3 is still processing lines of gcode, hence, the system loses it's reference to the zero point. We can stop Mach3, move the cutter back to the original zero, reset the X & Y axis then restart the job from a few lines before it stopped. Sometimes this will happen a couple of times during a job.It is obviously the hardware because Mach3 is not aware that it has stopped and keeps processing lines of gcode.
We have the work around but what is the solution? What could be wrong with the hardware?

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[john-100]

if you have used the machine for a while and one axis is faulty double check the cable connecting the stepper motor to the control box
cables that are flexed in use tend to break near to the connectors

not all 6050 CNC routers are built the same way
photos of the inside of your control box will help

some have a combined breakout board and stepper drivers manufactured as an all in one board
makes for a simple assembly

others use a breakout board and 3 or 4 individual stepper drivers
makes for more work assembling the control box but is less expensive to replace damaged parts

by swapping the interconnecting wires between the B.O.B and the drivers
you can test to see if an axis fault is the stepper driver or one of the BOB's outputs

John

[lesterb]

Thanks John,

It has topped on both an x axis and a yaxis run. This week we we're just milling a flat surface on a piece of timber so it was travelling in only one axis at a time but it stopped at diferent times in either axis.
The machine belongs to our Men's Shed and I will open the control box and photograph it when I go down there tomorrow.

[he1957]

We have a 6050 CNC router and are having problems with it stopping intermitently. Part way through a job it will stop moving but the cutter is still spinning and Mach3 is still processing lines of gcode, hence, the system loses it's reference to the zero point. We can stop Mach3, move the cutter back to the original zero, reset the X & Y axis then restart the job from a few lines before it stopped. Sometimes this will happen a couple of times during a job.It is obviously the hardware because Mach3 is not aware that it has stopped and keeps processing lines of gcode.
We have the work around but what is the solution? What could be wrong with the hardware?

By "stopping" do we assume you mean the axis stop moving?

Is this a new machine?
Has this always happened or is it something that has started recently?
Do you get the same behavior when you run the same job but only do air cuts?

Possible causes:

1. There is binding on the axis or axes
2. The acceleration/deceleration tuning ramps are too severe
3. Too aggressive in cutting
4. Not enough power for the motor drivers

It could be a combination of the above so start simple.

Some troubleshooting you can try:

Try air cutting the same job
Try reducing the feed/speeds
Try adjusting motor tuning values

[lesterb]

By "stopping" do we assume you mean the axis stop moving?

Is this a new machine?
Has this always happened or is it something that has started recently?
Do you get the same behavior when you run the same job but only do air cuts?

Possible causes:

1. There is binding on the axis or axes
2. The acceleration/deceleration tuning ramps are too severe
3. Too aggressive in cutting
4. Not enough power for the motor drivers

It could be a combination of the above so start simple.

Some troubleshooting you can try:

Try air cutting the same job
Try reducing the feed/speeds
Try adjusting motor tuning values

Thanks for your input.
We had problems initially because we setup some jobs wrong and the job over lapped the x and/or y limits. There are no limit switches so it came to a hard stop while Mach3 kept processing lines. This resulted in the same effect as this problem, it's zero reference point was shifted. In the past we have experienced tmes when instead of stopping it would just go off in a random direction unrelated to the job.
I'll try air cutting the same job tomorrow and report back.

[Sterob]

Open up the control box , disconnect mains power and check *every* terminal for tightness and give every wire a little tug. Make sure every connector is 'home' as well.
My guess is that you will come across more than one 'iffy' termination.

[lesterb]

Problem solved, I hope.
Today I ran the same job twice as an air cut and it still stopped intermittently at different places each time.
I then opened up the controller case and checked the connections. The only one that appeared loose was the spindle connection but that wasn't giving trouble. I reseated all connections, closed the box and air cut the job again. This time it didn't stop. I ran a few other jobs and they were fine. It looks like the must have been some dirty or poor connections.
It appears that this has solved my problem. Thanks to those that offered suggestions.

[Sterob]

Good Job. It will probably happen again one day. Also hardware will work loose ovr time.

Enjoy.