Jubilee - error then stops picking up tools

JoergS5

This post is deleted!

JoergS5

@BryanH I wish you success in improving the tool changer. The whole topic is interesting and will bring forward 3d printing!

BryanH

@JoergS5 Any reason that the M208 U0:200 can't be commented out? The Remote Elastic Lock is a dual limit switch environment and all moves are seeking an endstop.

JoergS5

@BryanH I would set it to the min and max values youre using which is M208 0:360

BryanH

@JoergS5 Done - let's see what happens

BryanH

ok, it seems it's getting worse.

Just ran the job wilst recording - caught on tape was a failed lock -

The machine attempted to pick up T0, the lock didn't finish the rotation, I can't tell if the limit switch triggered or not. I tightened up the lock by hand and noted at that time there was no holding torque on the U stepper - it was off. It finished the layer and go to the point where the tool change was called (15:42:32)
The carriage moved T0 to the park position and placed the tool on the post then tried to run the tool_unlock.g macro, nothing happened. There was no movement of the lock. There were no reported errors at this point.
The carriage did not pull back to move to the T1 pickup position.
The error was reported twice at 15:43:01 and T1 became the active tool, T0 was still mounted on the carriage, then the carriage pulled back and continued the job as T1.
T1 operated as if it were mounted on the carriage, extruding with an active part fan.
At the end of the current layer when the next tool change was called the system attempted to part T0 in the T1 parking location - The E-stop did not immediately respond and I pulled the plug.

Is there a better logging option than the console?

Thanks,

H2B

Seems like the latest firmware has some runaway tool change code somewhere to me.. There doesn't seem to be anything wrong with the macros and the config file(s) for a Jubilee setup..

poofjunior

@BryanH said in Jubilee - error then stops picking up tools:

, the lock didn't finish the rota

Good eyes, folks! My first suggestion would be the same: ensure that any commands sent to the U axis are be no greater than the limits defined in M208. On the stock configs, axis limit for U is set to 200, and invoking tool_lock.g rotates the U axis with an endstop sensitive search up to U=200. (Units are degrees for U.) Since locking is torque-sensitive, the locking position is unknown and will vary slightly with cycles, but it will be in this range.

Side note: The latest revision of the Lock only will actually hard-stop around ~120 degrees on the U axis. This translates to a full 180 degrees on the carriage twist lock side, which is now hard-stopped from material on the carriage back plate. At this point, the internal locking spring will be fully, stretched, clicking the internal limit switch and halting the move.

It sounds like this fix didn't work so my next suspicion would be a disconnected/loose wire somewhere in the U axis wire harness.

To test loose wires, I'd remove the KK connector and hook up a multimeter to both loose leads. Then, with the U axis disengaged (M18 U), I'd rotate the lock by hand with the knob. Only in cases where the limit switches are clicked should you break the connection. If you break the connection when the switch is not clicked, there's a break in the wire harness.

Other Thoughts

Based on when your prints fail, this only happens "sometimes." In my mind, this makes me think:

something in the real world that's not repeatable (loose wires, or something about locking since the exact position can vary over cycles)
something about the firmware, which may have a memory leak or uncaught edge case.

References

Jubilee Wiring Diagram, upper left section for U axis wiring harness

JoergS5

@BryanH Sorry to hear that the U matter was not the reason. I wish you good luck finding the reason.

A last idea: when the error occurs, check M122 to look whether there are hiccups for U or other errors. Jubilee has higher gear ratio and different speed/accel parameters, maybe the force is not sufficient.

BryanH

Solved!

Found that a set screw had backed out that was holding the fixed pulley in place on the stepper shaft.

We found it odd In the way it was manifesting.

Thank you everyone for the assistance.

poofjunior

My best guess as to why we got the " Error: G1/G2/G3: Intermediate position outside machine boundaries" error is because, in principle, each move should be terminated with triggering and endstop. A free-spinning shaft that would violate that principle.

Good to know how this hardware issue can manifest. I'll update the instructions to make sure folks double-check that their setscrews are threadlocked and biting down on the flat part of the shaft so this hopefully doesn't bite someone in the future!