Overload during operation

What is overload?

To protect itself, the spindle measures its own current, speed and temperature. If these parameters exceed their tolerances, the spindle will indicate an overload and eventually shut down. Before a shut down, an overload warning will be indicated by:

• the illumination of the setting wheel changing from blue to red, and 

• the overload on the console indicating as a percentage (shown below).*

*Only on the Precision Pro model

You can learn more about the overload feature here.

What should I do if my spindle overloads?

If the spindle overloads, SmartBench will automatically pause the operation, which turns the spindle off and resets the spindle.You may resume the job, however, if the cause of overload is not eliminated, then the spindle will overload again in the next operation. 

Continue reading to identify and eliminate various causes of spindle overload.

Step 1: Check the data connection between the ZHead and the spindle

A common cause of overload is if a data connection is loose, either in the cable or a socket. This can cause a false signal, which presents as overload.

Click here to learn how to check the spindle’s data connection.

You can also test with the speed control cable disconnected to run the spindle in manual mode with reference speeds available on the side of the spindle and then control it with the speed dial on the top, please see more in this article

Step 2: Does the overload occur immediately?

When powering on the spindle, does the spindle immediately (within 3 seconds) shoot to an excessively high speed, and shortly after present an overload? If so, read this article.

Or, if overload only happens in normal mid-job operation, continue reading. 

Step 3: Check that the spindle hasn’t been over-tightened

Over-tightening the spindle in the spindle clamp will increase the load on your spindle bearings and potentially overload the spindle.

It is essential that the exact instructions are followed to prevent over-tightening. Please refer to this article to ensure that you are clamping the spindle the correct amount with the T-driver (no more than 1/8th of turn after initial clamp).

Step 4: Evaluate the job parameters

The overload may be a genuine indicator that something may be wrong, and that something needs to be corrected with the job. Typical offenders include:

• Poor extraction (not enough clearance of chips, causing increased resistance)

• Blunt cutters (too much resistance for the spindle to cut the material)

• Over-demanding speeds and feeds (read this article which runs through recommended feeds and speeds and check that you are close to the recommended figures

• Check that you are using the Yeti Tool post processor if using Vectric or Fusion for your designs, and exporting in MM - see the below example in Vectric

Step 5: Contact customer support

If the problem persists, please contact customer support by submitting a support ticket with a video of the symptoms.