Falling off Z axis alignment mid print
So I have been having really good results for the last few months with Boxzy, but recently I am having a major new issue... Suddenly I am having spontaneous axis fall offs that I can't find any explanation for. I think that this issue has gotten progressively worse, I did have a few destroyed pieces along the way that I couldn't make sense of (but had stepped away from boxzy when the incident occurred so it was hard to say for certain), though in the last week or so, every milling job I have attempted has been ruined dues to the same issues.
Part 1 is that the limit switches for the carriage axes (XY) are doing something weird, I have been assuming due to wear and tear on the connector plug, it seemed a tad loose to me, and usually reaffirming that connection works here. So the two parts of this problem are 1) when homing the Y axis the limit switch occasionally will not trigger causing boxzy to repeatedly ram into the wall, and 2) I have had a few instances where the X/Y will fall off mid print leading to 3d prints out in mid air, and CNC tearing through workpieces at depth (no good on either account!) So I was wondering if anyone has come up with a good way to make that top connection a little more rigid, because I only see that problem getting worse.
Part 2 is a much bigger issue I can not make heads or tails of. The Z axis abruptly falls off the appropriate height mid print in CNC. This has lead to many destroyed workpieces, a couple of destroyed bits, and unnecessary wear on Boxzy I assume as well. I have watched it occur 3 times just now while milling a piece of acrylic and have no indicators of what is happening. It would be milling away fine, then suddenly it would not retract as high as it should and then would plunge 6x deeper than it should. What I do know: the limit switches are not being triggered accidentally, the milling head is secured firmly and not moving, the endmill is secured in the collet and not slipping. Anyone else have this issue, or any suggestions on troubleshooting, or what it might be?
Please help! I am finally getting up to speed with boxzy, and have made some wonderful objects, but this issue doesn't seem to be going away and makes boxzy essentially unusable. Thanks!
Is this a good question?