Shark HD3 Z-axis problems

[dgarvin]

Thanks for all of the responses!

I'll be investigating this further in the next few days with all the suggestions. I have found how to view the virtual zero adjusted file and I suspect I can use the ctrl-c/ctrl-v copy and paste to stuff it into a text file.

Are there any free g-code simulators out there that will allow me to visualize the virtual-zero adjusted file?

[dgarvin]

So, just to update what happened...

I did a ton of experiments with using virtual zero, not using virtual zero, manually jogging the spindle around, tramming a spoil board, manually editing the g-code and found absolutely nothing. Everything on the system is working properly: no play in the bearings, all connections are tight with no wiggle, router is (well, almost is) vertical, and there are no chips or other anomalies on the X/Y/Z worms.

I created several tap files to surface an entire board, cut various pockets, and measured the errors in lots of different cases. No problems. I never got around to messing with the post-processor because I wasn't finding issues with the g-code that was coming out.

I finally went and reloaded the same project, with the same board, under the same conditions, with the same tap file, and performed another virtual-zero procedure. I pulled up the adjusted code and reviewed all of the z-height settings and did the manual calculation on several points. Everything looked correct.

I said to myself "Screw it!" and ran the program.

What came out was the most perfectly cut sign I have ever made. No variations in z-height. No problems whatsoever. I spent several weeks chasing a problem that went away on it's own.

There is something in the code for the control panel coupled with the virtual zero that messes things up. I know this is going to pop up again but thanks to all the comments and suggestions here, I know where to go looking when it happens. Thanks again everyone!

[Bob]

One more afterthought...If it has not already been checked, Is the Z screw drive coupler tight. Is the setscrew seated tight on the flat portion of the shaft? If not, there could be future unwanted movement.
Bob

[jeb2cav]

Thanks for posting a followup. Too often the outcome never makes it here - so you never know. Bob's last comment is a good one as well. I have seen what I call 'free electrons' play a role over the years. In my case, I eliminated all of this with a UPS - primarily for power conditioning aspect vice battery backup.

[sharkcutup]

Dave,

You may want to be sure all is well grounded too. Static has been a culprit in some of the mysterious unexplained happenings in the operation of some of these machines. I have had a couple of unexplained occurrences early in the setup and operation of my machine but have not had any of those weird/mysterious occurrences since I have checked to make sure all is well grounded including the vacuum system.

Just more food for thought!!!

Oh and yes Thank You for the update on your progress that is something that is one that does not usually get to hear about or see here (unfortunate but true).

Sharkcutup