My Newb Plasma Table Attempted Build

PCW wrote: The per axis velocity and acceleration limits are higher than the stepgen velocity and
acceleration limits, This is the likely cause of the following errors. I would double the stepgen
velocity and acceleration limits and see if that fixes the errors.

Made those changes and no following errors. Ran a 2"x2" test square and same issue with the one side happened again, and it's always exactly the same amount short (1/32"). Could it be the microstepping?

is that with the reduced following error settings?

tommylight wrote: Also set the steplen and stepspace to at least 5000, preferably 10000 until you have everything in working order.

I did not see your post until after I tested. Will change them and try again.

PCW wrote: is that with the reduced following error settings?

Yes (FERROR = .01 and MIN_FERROR = .001 on all axis).

OK that's good that means the stepgen is following linuxCNCs command
within 0.01" at full speed and 0.001" when stopped so errors there can be
ruled out.

Is the error always on the same axis?

PCW wrote: OK that's good that means the stepgen is following linuxCNCs command
within 0.01" at full speed and 0.001" when stopped so errors there can be
ruled out.

Is the error always on the same axis?

Yes. It's always on the Y axis and seems to only be in one direction on the Y axis (in this case Y-). Per Tommy's recommendation I made one of these cuts while watching the DRO and it reflects the axis going the complete distance, although it doesn't in fact do so on the one side.

Tommy - I just made another test cut with those changes to 10000 and still the same result. Leaving them there until it gets sorted.

This has just become a challenge !
Can you post some pictures of the machine and some close-ups of the moving parts, please ?

tommylight wrote: This has just become a challenge !
Can you post some pictures of the machine and some close-ups of the moving parts, please ?

If this has only just now become a challenge, I'd hate to see the ones you've had before!

Please don't mind my mess. I hate showing this thing being a rookie and all, all of you guys have some really nice builds.

Making 2 posts due to the limitation on # of pics.

Remaining pics.

dvn4life1972 wrote: Please don't mind my mess. I hate showing this thing being a rookie and all, all of you guys have some really nice builds.

Have you seen some of my earlier builds? Some look much worse than this.
But the pictures do explain a lot, rubber bearings for one and the direct drive on that size of the machine are not good at all.
So now remains to check if those bearing do veer off course while moving, and setting the drives to 1 microstepping or full step, adjust the ini file to reflect that and do some more tests.
Be warned, at full step that machine is going to make some horrendous noises !