stepper motors on all axis are very loud, rough sounding

[Redshift.cnc]

Hello. I recently converted my old cncrouter parts 2'x4' standard table from mach3 to acorn. i have movement and have followed martys video on setting steps per rev and calibrating the inches per revolution. i can run a sample program but the motors sound horrible when moving. i am using the gecko G540 as a driver only and have adjusted the pots on the g540 to where they sound the best according to the gecko manual. but the motors still dont sound good at all. i spent all night trying to change things and watching videos to clean it up but I am just not sure what else to try now. machine ran fairly quiet before conversion. i must be missing something. thanks for any help or advice.
the motors on my machine are nema 23 OEmotor model 57ByGH633-07BS they are the 424ozin motors cncrp sends with their standard machines. I looked on the cncrp website to get the drive reduction and I have a 22tooth pulley on motor and 60 tooth pulley driving the gear engaging the rack. I have installed a rev4 acorn board and have the pro license for cnc12. my x axis is paired to A axis, cnc12 wanted it to be N axis so thats what it is now. my power supply is the meanwell 48v powersupply that came with my kit when I bought it in 2013, been running it the whole time.
i am attaching a cnc12 zip report from last night.
I tried to attach a video so you could here the sound but it wouldnt let me. I did post it on fb in the centroid acorn group in a response to Marty on a post I made there. you may be able to find it on there. when the axis move independently they dont sound as bad as when they are all moving at the same time when running a program. but they definitely dont sound like they did.

[Jay Morris]

Mine did the same when I went to acorn from mach3. I increased the steps from 1600 to 3200 and they sounded much better. But still at a slow feedrate they sounded rough. I have since replaced drivers and motors to leadshine closed loop, at 2000 steps they good.

[Redshift.cnc]

Thanks. I will try upping that to 3200 and see how it does. Everything I have read so far says the g540 should be at 2000steps per rev.
I plan on eventually switching to a closed loop system but cant at the moment.

[Dave_C]

Mine did the same when I went to acorn from mach3. I increased the steps from 1600 to 3200 and they sounded much better. But still at a slow feedrate they sounded rough. I have since replaced drivers and motors to leadshine closed loop, at 2000 steps they good.

I had the same issue when I converted from a very smooth running Mach 3 to Acorn and I have the closed loop leadshine steppers. I arrived at the same conclusion, 2,000 steps per rev on the motors and they got somewhat quitter. They are still a bit more noisy than when I ran them on Mach 3, I have no idea why! No lost step issues or anything else, just a bit more noise than I had before. (Same power supply, same mechanics, I just switched out the controller)

Dave C.

[LSGreen]

I’ve never used the g-540, but I do use leadshine closed loop drives and steppers (nema 34’s) at 8000. Never any noise and and very little heat. Very happy

[Dave_C]

I’ve never used the g-540, but I do use leadshine closed loop drives and steppers (nema 34’s) at 8000. Never any noise and and very little heat. Very happy

8,000! Interesting..

With a 5 turns per inch ball screw and 2,000 steps per rev, that gives me 10,000 steps per inch so that is .0001" per pulse. So here is the kicker! at 8,000 steps per rev, the micro stepping motors will not actually make that small a move. (try it and see for yourself)

I ran numerous test while I still had my DRO's on the Lathe bed and I could get .0001" moves at 2,000 PPR but it got unreliable when I tried higher PPR starting at 4,000.

Just sharing, maybe you setup works different as there are different drivers. I'm using NEMA 34's as well in 1,200 Oz In. ize.

Dave C.

[cnckeith]

Practical Application of maximum steps per rev for....

open loop stepper drives should not exceed 2000

closed loop stepper drives can go to 4000

closed loop servos can go to max native with no side effect but will limit max rate which may or not be an issue for a particular machine (depends on overall turns ratio)

read. viewtopic.php?f=63&t=1801

From one extreme to the other...
“So if my drive is capable of very high motor steps per rev...then why not just crank up the drive to the highest micro step resolution possible? That way I’ll have all the accuracy I need!” Well that may be true.. you will gain accuracy but most likely you will loose maximum feed rate in which the machine can move…. So, this is a simple balancing act… a trade off between torque, accuracy and top speed of the machine. If top speed is not important to you, then go for the more accurate set up but be mindful of reduced torque at higher steps per rev.

[Redshift.cnc]

Thanks for the replies. Yes I have cnc12 set for 2000 steps per rev. Mainly because that is what most have said the g540 needs. But it is unacceptably rough and loud. If it sounded just a little different i would probably just go with it. But this is basically loudly growling as it moves. Seems worse when running a program. When i move the axis individually it still sounds rougher than it used to but not as bad. When i get off my work rotation I will try to adjust the step per rev again up and down. Seems like the consensus is that is where to start.

[Redshift.cnc]

If there are any other suggestions please send them my way. I really want to get this machine running smoothly. I have put a hold on taking orders until I get it up again. Thanks

[Dave_C]

If there are any other suggestions please send them my way. I really want to get this machine running smoothly. I have put a hold on taking orders until I get it up again. Thanks

Have you tried inverting the pulse signal? (you do this in the Setup Wizard)

I can't remember for sure as it has been too long since I finished my project but I think the Leadshine products need the step pulse reversed.

Dave C.