Hi,

I am running a 4X8 industrial CNC Router -

I have just recently rebuilt the machine, upgrading from stepper motors to servo motors (Teco) and rewired the control box.

*** Prior to the rebuild I was using the same ESS with C25 - Smooth Stepper Terminal Board running Mach4 build 2522
The machine was running well at this time...

After installing the new servo motors (Teco) and re-configured and wired the control box, I upgraded the -

** BOB to the new C62 - Dual Port Multi-function Board from cnc4pc
** Upgraded the Mach4 software to build 3206
** Upgraded the ESS plugin from Warp9 to Version 186.

Computer - Fresh install 1 year ago running minimum software
2010 Toshiba Laptop running Windows7
Intel core i3 CPU M330 @ 2.13GHz
4.00 GB of Memory
64-Bit Operating system
Intel HD graphics (not sure of the memory).

G-code from Fusion 360 by AutoDesk

The Issue -
I was machining a large 3D mold out of MDF with feed rates about 250 IPM, while running the program I noticed that the tool path became jerky (not smooth in motion) and would slow down in feed rate and start to hesitate throughout the tool path. During this time the tool stopped and I looked at the screen and noticed that the code was continuing to run, and all of a sudden the tool started running again picking up the code many lines ahead. Ultimately cutting through the part in the wrong location. This hapend using Mach4 build 2914 and 3206

This has happened twice - first was during a 3D pocket clearing for roughing out the part and then again during the 3D scallop finishing cycle.

I have also noticed another issue during a different program -
The program finished, however the tool stayed down at .600 above Z Zero and the program was hung up on the last line M30. I was not allowed to stop the program or use the reset button (Mach4 was frozen). This happened twice...

I have also noticed another issue -
At the beginning of the program the "Tool change" screen appears.... Sometimes when I click OK the program will start immediately, other times it waits till I press cycle start.

So, I am not sure if this is a Mach4 issue, ESS or C62 issue, ESS plugin issue or a Computer issue; at this point I don't have any trust in my machine to operate as it should.

Wow, this does not sound good.  I have been upgrading my machine to Mach4, I also have the ESS and the C25 board and the machine seems very smooth.  I am also running Servo motors, I have not looked at the C62 board closely.  The first thing I would check is all the software on the PC, while the ESS is handling all the pulsing the Windows PC has to feed the trajectory moves to ESS, and it sounds like the ESS might be starving, not sure.  I don't have MACH4 licensed yet, because I don't have everything working at this point.  You might want to also check out the latest version of MACH4 which seems to be 4.2.0.3130.  If you look at the FTP site they show you what changed in each MACH4 load.

Russ

Another user with ESS and the C62 board complained with issues of them talking correctly in MACH4.  They sent him a new board, sounds like your is working better than his but could be something on that front as well.


http://www.machsupport.com/forum/index.php/topic,33277.0.html

Hi Russ,

Thanks for your reply, tho C62 Board seems to be working fine and the ESS does run very smooth while running 2D programs. The issue that I'm referring to happens while running very large 3D files, it runs fine at first and then as you said it seems to be starving or maybe we should refer to this as a bottleneck of information being passed to the ESS. Still not sure, I figured that the computer should be fine since it meets the software requirements -

Computer - Fresh install 1 year ago running minimum software
2010 Toshiba Laptop running Windows7
Intel core i3 CPU M330 @ 2.13GHz
4.00 GB of Memory
64-Bit Operating system
Intel HD graphics (not sure of the memory).

Unless the issue maybe with the video card, I cannot find the memory specs for it.

Thanks

RCR,

I am running ESS version 184, did not realize they released a newer version.  I do believe several users have been doing 3D files and have not heard that MACH4 had any issues on that front.  You might want to submit a sample 3D gcode file to the MACH4 support team, since the ESS hardware has been working on many machines and now has the third release of a plugin.  Not sure what changed between the last two ESS plugins but that could be a test for you to try 184 and see if it many any difference, just a thought.  I could not find the file that showed all the changes between releases on the WARP9 site.

Russ

I used a cnc4pc c32 bob with a smooth stepper and had nothing but trouble. Long story short, I bought a vital systems hicon bob and have not looked back. Just my experience.  I have a c32  for cheap if anybody is interested