I'm tired of this. Seriously considering asking for a refund.
Mach 4 keeps running away and breaking my tooling and workpieces. The latest incident is pictured below. Runaways have broken TWO 1/2" carbide bits, knocked my mill out of tram (more than once), bent a brand new ER40 collet holder and now trashed my home made 3" cutoff disk mandrell.
After repeated incidents, I can now anticipate when it might occur. In every instance, I was jogging from my wireless keyboard. If it fails to respond to a quick jog keypress, it is time to stop and restart Mach! What happens is this;
It will fail to respond to the keypress, so I bump it again and again, several times. All are very short keypresses, looking for a response. What has always happened is that it fails to respond several times, and then takes off in the attempted direction like a bat out of H***. Many times the distance is short to the crash point and I don't have time to hit the estop button before it crashes.
Here is what I think is happening. In every case the keypresses are very short and quick, simply looking for a response so I can position the bit. Sometimes I make as many as four or five unresponsive keypresses before it takes off. I think it is probably a delay in Windows (it's busy servicing some background task maybe....) or the wireless keyboard routine. AHA! Yes, say the Mach 4 programmers. It's not our fault. But wait! There is a serious deficiency in the Mach 4 programming if it is not continuously monitoring for the keypress and stopping movement IMMEDIATELY if it sees the key is not down. Apparently there is a windows cache which remembers keypresses (I've seen this in different programs) and implement they keypress when windows catches up. In Mach 4, that is a dangerous thing. The problem is, there seems to be NO keypress duration information retained that is associated with the keypress. If there were, what I should see when windows catches up is a series of short blip moves on the mill that correspond to the keypresses I made. Instead, Mach 4 just takes off in the indicated direction and never slows down until it hits something, which is more often a workpiece than a limit switch.
If Mach 4 were properly engineered, it would constantly be looking for confirmation that you were still trying to jog in the indicated direction and not just keep moving. Here are photos of the latest crash because of this.
The first photo, Mach4Crash, shows the ER40 collet holder that was bent when a 1/2" carbide bit crashed into it in a similar incident. You can see a short (2 minute) video of the impeccable runout this collet holder had when it was brand new here;
https://www.youtube.com/shorts/0zlhomrTiikNow, the runout after the crash is about two thousandths.
The next photo shows how this latest crash bent my home made cutoff disk mandrell. That was half a day of work down the drain.
The last photo shows how the crash broke off two of the tungsten contact points on my prototype magnet motor commutator.