Unfortunately the wiring is very simple in this machine. (It's just a small sign router.) There is a main control
board, with a couple of daughter boards (one for coms the other is the main brain) the encoder cables are plugged into
the main board, as are the limits, and some other misc IO. Then there are 3 ribbon cables one for each amp. That it.
I've checked the integrity of the ribbons and they all seem fine. There isn't a bunch of individual wires anywhere
that one could come loose and cause this. The amps only have 4 other wires 2 for the motors and 2 for the DC supply.
You might check the states of the inhibit outputs, that seems to be the only
way the drive signals a fault.
Most electrical hardware problems turn out to be connectors. Also - on machines that move/flex wire - proper strain
relief is a must - and a lot of equipment is made with the wrong type of wire - if it flexes too many times - like on a
router - wires break (usually right at the connector or some strain relief) .
There are people that make $pecial wire for robotics - but if you don't need documentation, just use wire with lots of
strands ( I've used 22ga with 60 strands) and strain relief to limit bend radius - the bits that matter. I used
silicone wire from bntechgo to fix a 3D printer that wiggled itself to death. (This is the type of wire they make test
leads out of so fidgeting technicians don't create intermittent connections) Automation Direct has some shielded high
flex wire.. (didn't have to buy a full reel).
But more important than the wire - it is where the wire meets the connector that fails - or where the connector meets
the circuit board. ( I once made a small pile of money fixing some Chrysler instrument panels - they would develop
cracks in the solder on the connector joints - intermittent - so very hard to diagnose - I had to use a microscope to
actually see most of the cracks - remove and replace the solder and all was well)..
PCB to connector joints with early no-lead solder were particularly bad ...
Most of the other wire in a machine - even if it vibrates a bit, you can get
away with MTW type stranding.
--
--------------------------------------------------------------------------------
Karl Schmidt EMail [email protected]
3209 West 9th Street Ph (785) 979-8397
Lawrence, KS 66049
Anger is an acid that can do more harm to
the vessel in which it is stored
than to anything on which it is poured.
-- Mark Twain
--------------------------------------------------------------------------------
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