When I load a Huge G Code file (more then a million lines) my Z axis start skipping steps!

The error can be reconstructed like this:
Startup Mach4 hobby and everything runs normal
Load a G Code file with more than 1 000 000 lines.
Jog the Z axis and it will start skipping steps.
Try to run the job and the axis (mostly Z) will skip steps, ruining the stock.

I have tried to replace the PC with a fast one and a LOT of RAM but the problem is the same.
Have updated Mach4 from 4.2.0.4809 to 4.2.0.5036 but problem is the same.
I am running ESS V 285
My PC is running Windows 11 Pro with the setup configuration that ESS setup guide is giving.

All other jobs runs normal and have done for more than a year.

Is there a limit on how many lines the Hobby version can handle?

Gaute Espeland
Norway
GMT +1

As far as I am aware Mach4 does not have a limit on the number of lines of GCode. However, there is an issue with memory available to the Graphics Card or Embedded Graphics Chip. Artsoft recommend a minimum of 512MB but 1GB or upwards may be more appropriate.
Or you could just add a screen button to toggle the Mach4 Toolpath Display OFF/ON. With Toolpath Display OFF your 1 million plus GCode files should run OK and without issue.

Tweakie.

However, there is an issue with memory available to the Graphics Card or Embedded Graphics Chip. Artsoft recommend a minimum of 512MB but 1GB or upwards may be more appropriate.

The PC have 64Gb RAM but maybe the Graphic card cant use it?

Or you could just add a screen button to toggle the Mach4 Toolpath Display OFF/ON. With Toolpath Display OFF your 1 million plus GCode files should run OK and without issue.

Thanks! I will try that and report back

This topic may be of some help...

https://www.machsupport.com/forum/index.php?topic=30928.msg214631#msg21463

Tweakie.

Hi,
I use a Dual core Atom without a graphics card to run my machine. It has 4G RAM fitted, but being only a 32 bit OS it can only address 3G....and of
that 3G about 0.5G is used for graphics. In short my machine PC is tiny and gutless and yet it works fine.

I regularly load and run jobs of 8MB and more without problems.

Craig

Wild guess..... is it possible that your G code contains many many moves so small that no actual step pulse gets generated, and therefore the machine is trying to consume motion commands faster than Mach and the ESS can process them?

This topic may be of some help...
https://www.machsupport.com/forum/index.php?topic=30928.msg214631#msg21463
Tweakie.

Yes I found this solution and tested it out yesterday.
And you where right; When jogging the Z-axis the problem is now gone!
Its a pity not to be able to see the Toolpath but its better than loosing steps.

I regularly load and run jobs of 8MB and more without problems.
Craig

This file is 35Mb and it looks to me (even if I have not tested the exact limit) that the problem comes when passing 30Mb.

Wild guess..... is it possible that your G code contains many many moves so small that no actual step pulse gets generated, and therefore the machine is trying to consume motion commands faster than Mach and the ESS can process them?

Probably not a bad idea. I had some problems before when the tolerance was set too high that the G Code file got very big.

But I dont understand how I can miss steps if no step is generated?

And this is the suggested solution from techsupport:

Can you try and run the file at half the speed that it is programmed ?   It sounds like the Z axis is missing steps due to the speed it is being commanded to travel at.

And the ticket is marked SOLVED...

The problem would have been caused by the processing overload, not specifically by a move so small that no step pulse would be generated.