Measured transient accelerations of approx. 2000 mm/s^2 when the max eeprom setting is 10 mm/s^2
I have recently rebuilt an old Wire edm machine into a relatively straightforward 3 axis 3d printer. While running with very conservative 10 mm/s^2 settings, I have measured transient accelerations in the x and y axis as high as 10 mm/s^2. These transient accelerations severally llimit the speed at which the machine can run and I have been unable to diagnose a hardware problem either electrical or mechanical causing these issues. I have come to suspect that their may be a software problem resulting from the slicer software at play which I am unable to diagnose. To that end I have compiled the eeprom setting and the Slic3r setting that were used during the test where I measured the high transient accelerations I have a .cvs file with the x and y acceleration data acceleration taken during the run. I even went so far as to video part of the run to highlight the visual and audio signature of these transient accelerations to disprove the notion that these are somehow sensor noise.
I am using a ramps v1.4 mounted to a mega 2560 control board. I am using 8820 drivers for the z axis and the extruder. For the x and y axis I am using a Toshiba TB6600 based drivers to drive a KL34H2160_62_8A (aprox. 1800 ozf*in stall torque and 42 V) on the x axis and an NEMA 2.3 motor on the y axis with approximately 400 ozf*in. The hotend is mounted such that it is fixed in the x-y axis while the bed moves in both the x and y axis. The combined table weight approximately 100-150 lbs and is driven by 4 mm/rotation ball screws which have been inspected and are working properly. I can provide more detail as required.
The errors are primarily occurring on the x axis and result in a missed half step such that the axis stalls skipping approximately 500 mm of travel before resuming. I am able to achieve travel speeds through jog settings as high as 50 mm/s with 50-100 mm/s^2 acceleration settings, but am unable to run prints at more than 15-20 mm/s speeds without incurring skipped steps. I have used the slic3r slicer for all prints.
Any suggestions or help would be greatly appreciated. I can provide pictures of the machine, eeprom settings, slic3er settings, acceleration data from one run, the gcode from that run and video of the run as necessary. but I'm unsure of the best way to provide them without just dumping them into the post as raw text.