On Mon, 2009-06-15 at 20:51 -0500, Wayne Patterson wrote:
> Kirk,
> Can you place a cooling fan or use a can of air on your controller at 
> about the time it is going to die ? Mainly on the chips responsible for 
> communicating with the PC.
> I have seen something like this on a industrial automated sewing 
> machine. And it ended up being a chip that communicated to and from the 
> main processor and the board that controlled the stepper driver boards. 
> It would work fine until the temp in the plant reached 80 degrees and it 
> would start acting strange. It took us almost a year to find exactly 
> what was wrong. And that was completely by accident. It's a long story 
> and I won't go into it here but I thought it might be something to look at.
> Just my $.02, and hope it helps.
> LennyWayne

Thanks for your input Lenny. I worked on the machine today and the PC I
used to replace the original PC was having a hard time doing anything
properly. I don't know why, but I am getting the feeling that the hard
drive was not working properly. I removed this PC in order to work on
the first. I brought the second back up to the office, it wouldn't boot
the first time, but has run perfectly since reboot. I'm beginning to
think about EMI suppression and power conditioning. I have a bit of a
jury rig right now. I wanted to use the machine before finalizing
everything, but it may be time to get proper enclosures and such. It's a
pain not having a working mill, I may have to get another one.:)

... Thinking a little more, I was thinking that when the program gets to
the nineteenth hole,maybe a buffer fills or whatever, then goes to use
the swap and craps out, but then, I thought I should be able to find an
error message to that effect. I found nothing in dmesg, so maybe I need
to look somewhere else (I just remembered /var/log), or my guess is
wrong. I bet House could figure this out, but of course it would take
him just under an hour to do it. Just think, he could solve two cases if
there where no commercials.

My plan now is to get the original PC back in, see if I can get it to
fail (shouldn't be hard). Run a simulated configuration, if it fails,
then bring it to the office and try again. I may have to bring the whole
mill up here if that fixes it.

-- 
Kirk Wallace
http://www.wallacecompany.com/machine_shop/
http://www.wallacecompany.com/E45/index.html
California, USA


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