I've rewired every cable in the whole machine and moved the control electronics to their own control cabinet to separate stepper motor drivers and the Ethernet smoothstepper card along with the BOB boards that also are grounded with computer and cabinets, ensuring that there are no ground loops
I'm using only shielded cables that are grounded in the signal end for everything, home switches, VFD USB rs485 communication, motor cables, spindle power cable and so on.
I've upgraded the computer to:
Intel i5 6500 3.2Ghz
16GB 1600MHz Ram
128GB SSD Drive,
Mach 4 is the only thing that is installed on the computer, along with drivers, and other necessary things
I've followed the guide for "how to run mach 4 reliable"
I've tried to change the buffer size and Plugin frequency in ESS plugin Configuration under the "General Tab"
following recommended values.
I can send the gcode file privately. for closer inspection, I use the Fusion 360 and the Postprocessor for mach 3 and have never experienced any problems before? The problem usually occurs at line 17000-19000 as the timeline change says in the log file,
can also see a sudden jump on the line viewing window from line 5000 up to 20000 and back again and when it happens and then the gcode rewinds. spindle still running, is just like the machine stops moving for a second and then moves on but only sometimes, and then that happens again and it locks up, but mach is still operational and I can jog the machine and everything after I reset the E-stop condition
Log file "Try 1" fault occours between 19sec and 36sec
2018-09-07 13:29:32.308 - Loggging Enabled.
2018-09-07 13:29:35.762 - API: mcCntlCycleStart() called.
2018-09-07 13:29:35.863 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:29:35.863 - S_IDLE_on_exit
2018-09-07 13:29:35.863 - ACTION_start_cycle
2018-09-07 13:29:35.864 - S_FILE_RUNNING_on_entry
2018-09-07 13:29:35.864 - S_FILE_RUNNING2_on_entry
2018-09-07 13:29:35.864 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:29:42.178 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 0.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 1.
2018-09-07 13:29:42.178 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:29:42.178 - Requesting a stopped report for motor 2.
2018-09-07 13:29:42.178 - Waiting on SetStill...
2018-09-07 13:29:42.586 - All motors marked as still.
2018-09-07 13:29:42.586 - Waiting on SetStill is Done!
2018-09-07 13:29:42.588 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:29:42.588 -
2018-09-07 13:29:42.588 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.588 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Required notification.
2018-09-07 13:29:42.590 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:29:42.590 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:29:42.591 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:29:42.591 -
2018-09-07 13:29:42.591 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.591 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:29:42.594 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:29:42.594 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:29:42.594 -
2018-09-07 13:29:42.594 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.594 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:29:42.595 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:29:42.610 - All motors marked as still.
2018-09-07 13:29:42.661 -
2018-09-07 13:29:42.661 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:29:42.661 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:36:06.139 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 0.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 1.
2018-09-07 13:36:06.139 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:36:06.139 - Requesting a stopped report for motor 2.
2018-09-07 13:36:06.140 - Waiting on SetStill...
2018-09-07 13:36:06.521 - All motors marked as still.
2018-09-07 13:36:06.521 - Waiting on SetStill is Done!
2018-09-07 13:36:06.522 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:36:06.522 -
2018-09-07 13:36:06.522 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:36:06.522 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:36:06.522 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:36:06.522 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:36:08.015 - Done. Spindle.cpp:356
2018-09-07 13:36:08.015 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:36:08.026 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:36:08.026 - S_FILE_RUNNING2_on_exit
2018-09-07 13:36:08.026 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:36:08.026 - S_FILE_RUNNING_on_exit
2018-09-07 13:36:08.026 - ACTION_stop
2018-09-07 13:36:08.042 - S_IDLE_on_entry
............................................................................
Log file "Try 2" With Stop/Emergency button hit. problem occurs between 46sec and 53sec
2018-09-07 13:46:05.722 - Loggging Enabled.
2018-09-07 13:46:14.626 - API: mcCntlCycleStart() called.
2018-09-07 13:46:14.727 - Attempt transition from "Idle" on event "Cycle Start" MachAPI.cpp:2603
2018-09-07 13:46:14.727 - Signal id 1127, (Jog Enabled), changed from HIGH to LOW.
2018-09-07 13:46:14.727 - S_IDLE_on_exit
2018-09-07 13:46:14.727 - ACTION_start_cycle
2018-09-07 13:46:14.728 - S_FILE_RUNNING_on_entry
2018-09-07 13:46:14.728 - S_FILE_RUNNING2_on_entry
2018-09-07 13:46:14.728 - Signal id 1114, (Gcode Running), changed from LOW to HIGH.
2018-09-07 13:46:21.211 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 0.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 1.
2018-09-07 13:46:21.211 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:46:21.211 - Requesting a stopped report for motor 2.
2018-09-07 13:46:21.211 - Waiting on SetStill...
2018-09-07 13:46:21.475 - All motors marked as still.
2018-09-07 13:46:21.475 - Waiting on SetStill is Done!
2018-09-07 13:46:21.476 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:46:21.476 -
2018-09-07 13:46:21.476 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.476 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.512 - All motors marked as still.
2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from LOW to HIGH.
2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Required notification.
2018-09-07 13:46:21.514 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:46:21.514 - Signal id 1121, (Tool Change), changed from HIGH to LOW.
2018-09-07 13:46:21.515 - >>>>> ESS received a Tool Change Done notification.
2018-09-07 13:46:21.515 -
2018-09-07 13:46:21.515 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.515 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:46:21.516 - API: mcSpindleSetDirection(inst = 0, dir = 1) called.
2018-09-07 13:46:21.516 - Signal id 1142, (Spindle Fwd), changed from LOW to HIGH.
2018-09-07 13:46:21.516 -
2018-09-07 13:46:21.516 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.516 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:46:21.516 - Signal id 1141, (Spindle On), changed from LOW to HIGH.
2018-09-07 13:46:21.613 -
2018-09-07 13:46:21.613 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:46:21.613 - >>> ESS: Relay Mode - 'Spindle Motor Dir' set to Forward.
2018-09-07 13:53:56.933 - Controller::RunCanonBuffer called AddStopReportRequest() RunCanon.cpp:76
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 0 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 0.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 1 motors.
2018-09-07 13:53:56.933 - Requesting a stopped report for motor 1.
2018-09-07 13:53:56.933 - Requesting a stopped report for axis 2 motors.
2018-09-07 13:53:56.934 - Requesting a stopped report for motor 2.
2018-09-07 13:53:56.934 - Waiting on SetStill...
2018-09-07 13:53:57.171 - All motors marked as still.
2018-09-07 13:53:57.171 - Waiting on SetStill is Done!
2018-09-07 13:53:57.172 - Signal id 1142, (Spindle Fwd), changed from HIGH to LOW.
2018-09-07 13:53:57.172 -
2018-09-07 13:53:57.172 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:53:57.172 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:53:57.173 - Signal id 1141, (Spindle On), changed from HIGH to LOW.
2018-09-07 13:53:57.173 - Waiting 1.500000 seconds for spindle to stop... Spindle.cpp:351
2018-09-07 13:53:58.669 - Done. Spindle.cpp:356
2018-09-07 13:53:58.670 - Waiting for motions to complete: MC_CANON_REWIND. GcodeExec.cpp:745
2018-09-07 13:53:58.679 - Attempt transition from "File Running" on event "Stop" GcodeExec.cpp:765
2018-09-07 13:53:58.679 - S_FILE_RUNNING2_on_exit
2018-09-07 13:53:58.679 - Signal id 1114, (Gcode Running), changed from HIGH to LOW.
2018-09-07 13:53:58.679 - S_FILE_RUNNING_on_exit
2018-09-07 13:53:58.679 - ACTION_stop
2018-09-07 13:53:58.696 - S_IDLE_on_entry
2018-09-07 13:54:14.554 - API: mcScriptExecute() called. filename "m5.mcs" async 0
2018-09-07 13:54:14.556 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.556 -
2018-09-07 13:54:14.556 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.556 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.582 - API: mcCntlCycleStop() called.
2018-09-07 13:54:14.585 - API: mcSpindleSetDirection(inst = 0, dir = 0) called.
2018-09-07 13:54:14.586 -
2018-09-07 13:54:14.586 - >>> ESS: Spindle PID is not available in Relay Mode.
2018-09-07 13:54:14.586 - >>> ESS: Relay Mode - Spindle stopped, 'Spindle Motor Dir' not changed.
2018-09-07 13:54:14.586 -
2018-09-07 13:54:14.586 - $$$ ESS: Mach4 had a Cycle Stop - Force Output Stop Sates Now
2018-09-07 13:54:14.586 - $$$ ESS: Finished processing the Stop Event
2018-09-07 13:54:14.586 -