Hey guys,
So we tried all of that, and we are still having issues.
- Loosened all of the set screws on the pulleys (12 of them)
- Detached X/Y motors to get to said screws
- Set pulleys on X/Y motors, loosely attached motors back on to frame
- Set Motor pulleys on top rods, checking for alignment with pulleys on motors.
- Starting on one side, squared axis using the wooden spacers, tightened pulleys
- Continued on the other three sides
- Confirmed that all four sides were square
- Tightened down the X/Y motors to tighten belt
- Added the spring belt tensioners included in the kit (I didn't recognize what they were when I first put the printer together).
- Used some light machine oil to lubricate all of the top rods (four outer rods and two cross rods) This had a major impact on how smooth the movement felt with the machine off
- Slowed down the print speed to 60 mm/s
- Used both Cura 15.04.2 (what we had been using) and Cura 15.04.4 (Latest from Ultimaker)
And we got this result:
As an observation, one of the belt tensioners looks like it may be interacting with one of the sliding blocks attached to the same belt. This is the same belt that is having slipping issues. We tried to move the pulleys to give some more room, but it looks like the block pulls the belt back towards this rubbing point. You can see the interaction below:
To answer SandervG's question, there was no indication on the controller that anything had happened.
Any other ideas on how to troubleshoot this? I appreciate all of the suggestions so far.