Sven Wesley wrote:
> I can cannot see any changes in speed even if I push put all my body weight
> on the Z-axis, it just runs super easy and the motors never gets warm. It
> doesn't _seem_ to be a force/power problem.
> I have put so much money and time in building a servo system. It's REALLY
> annoying if I have to go back to steppers. To me, these eBay-items looks
> pretty small too. Are they really going to make it?
>   
I am now CONVINCED that your problem is a step timing issue, possibly a 
step-vs-direction
setup time issue.  I am also sure the Rutex has some kind of a fault 
output, but you may not be using it.
I remember the fault window is programmable, as opposed to Gecko's fixed 
limit.

If you were to put stepper motors and a stepper drive on the machine, 
you might well have
the exact same problem - many people have.  The timing of the 
step/direction pulses MUST
meet what the manufacturer needs.  If the manufacturer's specs are 
non-existant or just wrong,
that makes fixing this much harder.

The basic problem is either the drive fails to detect some of the step 
pulses, often just after a direction change,
or counts a step pulse in the wrong direction.  Gecko once had a problem 
with the pulse multiplier in their
Gecko 210 (stepper) and 340 (servo) where if the direction changed while 
the multiplier was still putting out
multiplied pulses, those steps would go in the wrong direction.  It led 
to errors in fractions of the commanded
steps.  The fix was to either remove the pulse multiplier or make sure 
the software didn't generate a step pulse
for some specific time after a direction change.  That's just one 
possible way such a problem could happen.

Unless somebody knows the specific settings for your drives, you may 
need to systematically explore the
range of settings and motion to see if you can identify which adjustment 
affects the problem.  And, if you find a setting that
makes it WORSE, that may be an important clue to what the underlying 
problem is.

You can make a chain of short moves in the same direction, with a pause 
between each move, and see if there
is no error.  Then, make moves back and forth, with delay between each 
move - again, check for error.
Then, move back and forth with NO delay between moves.  Does this make 
the error worse?  If you see it is
worse with back and forth moves with no delay than either of the other 
movements, that is a BIG clue it
has something to do with step timing vs the direction signal.

Jon

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