Hello, CarveWright users!
I am attempting (and have been for many months now) to use my CW as a sort of 3D-printer, using 3D modeling software to create a virtual representation of the thing I want to make, then taking cross-sectional slices of it, converting those into grayscale height maps, and importing those as patterns into the Designer software. I've seen others use this method with a CarveWright to great effect. Unfortunately, I've continually run into severe-enough inaccuracy along the X axis that I have, to date, created no usable cross-sections. The X axis dimension of each cross-section is always too short and never by the same amount (i.e. I can't just overscale something to compensate for this). I have done a great deal of searching through these forums' archives, the machine manuals and guides, YouTube videos, and so on to attempt to self-diagnose the issue, but after today's unsuccessful carve (four hours with great hope that I had finally resolved the issue, only to see a 7mm difference between expected and actual X-axis dimensions), I have to admit that I simply am out of ideas.
I have tried the following:
- Checking, re-checking, triple-checking, and quadruple-checking my source measurements. They're right in my 3D software, they're right in my image editing software, they're right in Designer. It definitely ain't the source.
- Leveling the head. I initially also had issues with varying depth along the Y axis, but leveling the head resolved this (along with bullet #4).
- Cleaning and re-greasing everything. I also measured low head pressure at first. After cleaning and re-greasing, this seems to have gone away, but now I frequently see high (as in > 115 pounds!) head pressure if I allow the "clutch" to click more than two or three times. If I just click it a few times, I measure ~84 pounds.
- Removing, cleaning, and re-seating the sandpaper belts. They were, initially, partially rolled under on one side.
- Changing the type of board. I started out using 1/2" MDF, but noted that MDF tended to "shred" when it got too thin. I switched instead to 3/4" (really, 11/16") plywood, which did away with the shredding problem.
- Manually calibrating the X axis. I bought a 36" board specifically because it claimed at 36" length that I verified with two separate tape measures. The CW measured its length as 36.27925" (average of four measurements, each of which was slightly different). Using the instructions for manual X axis calibration, I adjusted the offset from 890.213 to 899.521, which resulted in a measurement of 35.958", which I was happy with (0.042" = 1.07mm, which seemed pretty accurate).
- I subsequently did a test carve that seemed to come out more-or-less correct with ~2mm total inaccuracy, but on all axes. Since the 1/16" carving bit itself is nearly 2mm across, so I figured this was probably simply within expected tolerance.
- Today's carve came on the heels of that test carve and resulted in the aforementioned 7mm variation (specifically, a piece that should be 19.66cm wide came out at 19cm even; that's far too much slop for what I'm trying to do).
- I have since reset the offset to default (I haven't carved since doing this, though). In all of these tests
- All of these tests and carves were done with a board 14.5" wide.
I've attempted to carve some unpleasantly large number of these cross-sections at this point, using different configurations on the board. All of them always come out wrong along the X axis (and only the X axis) and never in ways that are consistent enough to simply "smooth over" after the fact.
I've also variously encountered the following errors along the way:
- X axis stalls. These were resolved after the thorough machine cleaning.
- Tracking roller errors. These seem to happen only on longer boards (the 36" one caused it a couple of times) and I hit a spate of them at one point until I realized that I simply hadn't firmly re-tightened the screws attaching the tracking roller assembly to the guide plate. Derp.
- Back roller stuck. No idea what's causing these. They've started happening in the last day or so when attempting to measure short (~15") boards and they only occur once the board has left the back roller. Is there a minimum board length?
- Power fluctuation issues. Resolved by changing outlets.
I am somewhat suspicious that there is a problem in the X drive motor. I ran the X-axis "user test" five times in a row and each time got different values (which, unfortunately, I have not found any information on interpreting, short of "send this in to the techs if they ask for it," which is not terribly enlightening).
Code:
A=125.37 M=181.63
A=124.34 M=178.41
A=123.66 M=175.96
A=123.22 M=178.23
A=122.93 M=176.16
My assumption is that these numbers should be much closer together than they are and that the disparity between them is indicative of at least part of the problem.
I inherited this machine from a friend moving cross-country. As an inherited device, I don't have the option to simply "send it in" for fixing; I'm kind of on my own (along with whatever kind help the folks here on the forums can offer) when it comes to repairs. And, as a cherry on top of that cake, I'm not really in a position to lay out a bunch of cash for replacement components just now, either. I'm hoping there's some kind of home repair or calibration or cleaning or cheap hardware store replacement part that will be the magic bullet to all my woes here.
Additional miscellaneous info that may be relevant:
- Machine type: A (yep, old)
- Power-On time: 265 hours
- Servo time: 192 hours
- Cut time: 185 hours
- Firmware: Rev: 1.187.10870, Build: 0417:090305, Secondary Rev: 7
Any advice anyone could offer would be very much appreciated!