I just upgraded my Lead 1515 machine (about five years old) to the x32 controller to enable 4th axis. Since the upgrade, my machine has failed about 50% of it's jobs with unplanned cuts (3 or 4 axis) and has cost me around $210 in materials due to failures, plus damage to the 4th axis due to bit collisions. This was not an issue before upgrading. The failures have two main modes: 1. Shifting the entire cut forward or backward on Y by a few inches at a random point in time. It is consistantly the same distance (by eye) every time it happens. I can run the same eight hour file multiple times and sometimes it works fine and other times it offsets part way through and ruins the entire piece. 2. Inaccurate motion on X and Y. When cutting a grid or v-carving a line art design the lines often don't line up. A series of straight lines in the cut file, which looks like this in the preview ------------, shifts side to side with each segment and gives a random effect like this __---_-_-_---_-- Recent changes include: • x32 board • x32 firmware • x32 Fusion 360 post processor • 4th axis machine config for Fusion 360 • Paired Y motors to Y1 so rotoary A can be on Y2 • Replaced USB cable (old one wore out) I thought maybe it was stalling Y but I can run the same 8 hour cut multiple times and sometimes it offsets and sometimes it doesn't. I've spent about a week trying to figure this out. I've tried: • Clean and re-sqaure machine • Adjust wheel tensions and add dry-lube • re-download post processor and machine config • Update Fusion 360 • Validate no collisions • Video record entire jobs to look for issues when failing (difficult to see any issues) • Re-run jobs (about 50% fail) • Adjust driver amps • Adjust feed-rate • Adjust spendle speed • Post files from different computers
i vote for static electricity caused by the vacuum. move your vacuum hose away from all other wiring (overhead hanger works well) ground the vacuum hose to prevent buildup
As above, especially as I note you replaced the usb cable - might the quality/length of the replacement be a factor? Alex.
Did you transfer the maximum speed and (importantly) acceleration settings for X, Y and Z from the old controller to the new? Even if you did, the Y axis may need re-tuning to reflect the change from two motors to one. As a diagnostic measure, you could try halving the speed and acceleration settings and see if you still experience failures.
