This seems an appropriate place to post this little story:
About a week ago I upgraded to ball bearing carriages and M5 z rod, and after the big reassembly (every moving part was removed from the frame at one point...) I had a weak y-axis, which I finally fixed by realising that I hadn't tightened up the set screws on my direct-drive coupler. I'd spent a whole afternoon chasing VREF, alignment, cleaning of rails, belt tension... Felt like such a fool!
After a bit of a break, flash forward to last night - I had the m3x50mm problem with lawsy's carriage, so the extruder was held on mainly with tape. Last night I was trying to print a variation to replace it, but somehow couldn't get rid of slips in the x axis. Now this never happened before, so I thought maybe the ball bearings were still wearing in a bit and a bit sticky, was feeling like I might have bitten off a bit much all at once.
Starting to worry a bit, given I'm trying to print a case for a clock as a present by wednesday, and I've already been in trouble for late delivery, so every hour counts...
This in mind, I tuned VREF to get a good sound and a bit more force (figuring the bearings may have changed the sweet spot), and being overzealous / in a hurry nearly cooked the x motor - but it was still slipping (particularly badly when the driver tripped out on thermal).
I then added a desk fan and a heatsink to the x driver, as a matter of desperation. Still slipping.
Let everything cool off (more time wasted), retuned VREF back down to run cool as possible, looked good for a bit then... Still slipping.
Sliced the model at 30 mm/s (SimCity Turtle Mode - so useless) to reduce the forces (good for the wobbly extruder though). Still Slipping.
While leaving the x motor to cool back down another couple of tries later I thought I might jam a multimeter thermocouple in there to see how it was doing (too hot to touch still).
At this point I noticed the x pulley was riding right against the flange, so decided to lift it up a little. When I put the allen key in the set screw to loosen it, I notice it's already loose. DUUUUUUUHHHHHHH!!!!
I think I need a label on the front of the case: "CHECK YOUR SET SCREWS."
Also: "IT'S LATE, YOU'RE TIRED, GO TO BED."
SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi