Filament sensor triggers for the wrong extruder

adammhaile · 4 Apr 2022, 15:11

I'm trying to setup some simple switch filament sensors on my IDEX machine, so I have 2 sensors. One is connected to the main 6HC (which controls the left tool) and the other to the 3HC expansion (which controls the right tool).

Sensor setup is as follows:

M591 D0 P1 C"0.io4.in" S0 ;left tool
M591 D1 P1 C"1.io5.in" S0 ;right tool

They start disabled but are enabled in start.g
However, as soon as a job starts it triggers a pause and says:

Error: Filament error on extruder 0: noFilament

Except, I tested first turning on only the left sensor (which has filament) and it works fine.
But if I then enable the right sensor (with M591 D1 S1) which doesn't have any filament loaded it will immediately pause the print with the no filament error above.

I feel this partly means I need to have it only enable the sensor when that particular tool is selected, which I will do - however the main problem I'm seeing here is that it's reporting the error for extruder 0, not extruder 1.

Any thoughts as to what would cause that?

Here's my full config.g

; Configuration file for Duet 3 (firmware version 3.3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.10 on Mon Feb 14 2022 00:04:10 GMT-0500 (Eastern Standard Time)

; Load global vars
M98 P"globals.g"

; General preferences
G90                                                         ; send absolute coordinates...
M83                                                         ; ...but relative extruder moves
M550 P"Rancor"                                              ; set printer name

; Audio Player Serial Config
M575 P2 B57600 S2                                           ; Setup UART on IO_1 to 57600 baud

; Setup Lights
M950 P0 C"0.out9" Q4000

; Setup Servos
M950 S1 C"0.io7.out"
M280 P1 S100

; Wait a moment for the CAN expansion boards to start
G4 S2

; speak greeting
M800 F"greeting"

; Drives
M569 P0.0 S0                                                ; Left Y
M569 P0.1 S1                                                ; Left X
M569 P0.2 S0                                                ; Left Extruder
M569 P0.3 S1                                                ; Left Z
M569 P0.4 S1                                                ; Right Rear Z
M569 P0.5 S1                                                ; Right Front Z
M569 P1.0 S1                                                ; Right Y
M569 P1.1 S1                                                ; Right X
M569 P1.2 S0                                                ; Right Extruder

M584 X0.1 U1.1 Y0.0:1.0 Z0.3:0.4:0.5 E0.2:1.2               ; set drive mapping
M350 X16 U16 Y16 Z16 E16:16 I1                              ; configure microstepping with interpolation
M92  X160 U160 Y160 Z1600 E397:397                          ; set steps per mm
M566 X400 U400 Y400 Z100 E1500:1500                         ; set maximum instantaneous speed changes (mm/min)
M203 X10800 U10800 Y10800 Z900 E3600:3600                   ; set maximum speeds (mm/min)
M201 X500 U500 Y500 Z100 E1500                             	; set accelerations (mm/s^2)
M906 X1400 U1400 Y1400 Z1200 E1100:1100 I75                 ; set motor currents (mA) and motor idle factor in per cent
;M84 S30                                                    ; Set idle timeout

;Leadscrew locations
M671 X-13.7:343.8:343.8 Y160:287.5:32.5 S7.5

; Axis Limits
; TODO - these are wild guesses at this point for X
; will need to change mins to negatives
M208 S1 X-85 U0 Y0 Z-2                                            ; set axis minima
M208 S0 X405 U450 Y345 Z600                                      ; set axis maxima

; Endstops
M574 X1 S1 P"0.io2.in"                                        ; X homes low end
M574 U2 S1 P"1.io2.in"                                        ; U homes high end
M574 Y1 S1 P"0.io3.in+1.io3.in"                               ; Y has dual motors and endstops
; TODO - setup homing files https://duet3d.dozuki.com/Wiki/ConfiguringMultipleIndependentXcarriagesCartesian#Section_Homing_files

; Z-Probe
M558 P5 C"^0.io5.in" H2.5 F250 T6000                            ; set Z probe type to switch and the dive height + speeds
G31 P500 X0 Y0 Z1.2                                   ; set Z probe trigger value, offset and trigger height
M557 X15:315 Y20:300 S75:70                                    ; define mesh grid

; Heaters
; Bed
M308 S0 P"0.temp0" Y"thermistor" T100000 B4240                ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"0.out0" T0                                          ; create bed heater output on out0 and map it to sensor 0
M307 H0 B0 R0.611 C647.0 D2.25 S1.00                          ; enable bang-bang mode for the bed heater and set PWM limit
M140 H0                                                     ; map heated bed to heater 0
M143 H0 S120                                                ; set temperature limit for heater 0 to 120C

; Left
M308 S1 P"0.temp1" Y"thermistor" T100000 B4725 C7.06e-8       ; configure sensor 1 as thermistor on pin temp1
M950 H1 C"0.out1" T1                                          ; create nozzle heater output on out1 and map it to sensor 1
; M307 H1 R2.616 K0.237:0.348 D5.69 E1.35 S1.00 B0 V23.9      ; disable bang-bang mode for heater  and set PWM limit
; M143 H1 S285                                                ; set temperature limit for heater 1 to 280C

; Right
M308 S2 P"1.temp0" Y"thermistor" T100000 B4725 C7.06e-8     ; configure sensor 2 as thermistor on pin 1.temp0
M950 H2 C"1.out0" T2                                        ; create nozzle heater output on 1.out0 and map it to sensor 2
; M307 H1 R2.616 K0.237:0.348 D5.69 E1.35 S1.00 B0 V23.9      ; disable bang-bang mode for heater  and set PWM limit
; M143 H2 S285                                                ; set temperature limit for heater 2 to 280C

; Fans
; left HEF
M950 F0 C"0.out7"                                             ; create fan 0 on pin out7 and set its frequency
M106 P0 S1 H1 T45                                         ; set fan 0 value. Thermostatic control is turned on
; Left PCF
M950 F1 C"0.out8"                                             ; create fan 1 on pin out8 and set its frequency
M106 P1 S0 H-1                                              ; set fan 1 value. Thermostatic control is turned off
; Right HEF
M950 F2 C"1.out7"                                           ; create fan 2 on pin 1.out7 and set its frequency
M106 P2 S1 H2 T45                                         ; set fan 2 value. Thermostatic control is turned on
; Right PCF
M950 F3 C"1.out8"                                           ; create fan 3 on pin 1.out8 and set its frequency
M106 P3 S0 H-1                                               ; set fan 3 value. Thermostatic control is turned on

; Tools
; Left
M563 P0 S"Left" D0 X0 H1 F1                                    ; define tool 0
; G10 P0 X-71.5 Y-20.6 Z0                                        ; set tool 0 axis offsets
G10 P0 X0 Y0 Z0
G10 P0 R0 S0                                                   ; set initial tool 0 active and standby temperatures to 0C

M591 D0 P1 C"0.io4.in" S0								; setup T0 filament sensor

; Right
M563 P1 S"Right" D1 X3 H2 F3                                   ; define tool 1
; G10 P1 U-0.3 Y-20.6 Z0.35                                      ; set tool 1 axis offsets
G10 P1 U0 Y0 Z0
G10 P1 R0 S0                                                   ; set initial tool 1 active and standby temperatures to 0C

M591 D1 P1 C"1.io5.in" S0								; setup T1 filament sensor

; extra sensors
M308 S10 Y"mcu-temp" A"MCU"                           ; defines sensor 10 as MCU temperature sensor

; set base tool names
M98 P"tools/t0.g" 
M98 P"tools/t1.g"

; load variable tool configs
M98 P"tools/setup.g"

; Ensure T0 loaded
M98 P"soft_load_tool.g" S0

Phaedrux · 4 Apr 2022, 19:51

Try using your tool change files to enable and disable the monitor so that only the active tool has it enabled.

adammhaile · 4 Apr 2022, 19:56

@phaedrux said in Filament sensor triggers for the wrong extruder:

Try using your tool change files to enable and disable the monitor so that only the active tool has it enabled.

Ok - I've since done that... However:

This enables the monitoring if a tool is selected even if I'm not currently printing. Which means if you are unloading filament it will trigger an error message. I guess I need more conditional logic so it only enables it when the tool is selected AND it's currently printing.
There's still the issue that it specifies the wrong tool when the error is thrown for my right (T1) tool. And it calls filament-error0.g instead of filament-error1.g. I realize I can also just use filament-error.g which I will do - just trying to point out that it's noting the incorrect tool when throwing the filament error. Is that something that needs to be fixed in firmware or am I just doing something wrong?

Phaedrux · 4 Apr 2022, 20:10

Something like if state=processing might be enough. See if that leads you in teh right direction.

adammhaile · 4 Apr 2022, 20:25

@phaedrux said in Filament sensor triggers for the wrong extruder:

Something like if state=processing might be enough. See if that leads you in teh right direction.

Ah, cool - there wasn't a "printing" state so I wasn't sure.
What I had come up with so far was:
if job.build != null

Any thought though as to why it's triggering for the wrong tool? That's my real concern here.

Phaedrux · 5 Apr 2022, 04:31

@adammhaile said in Filament sensor triggers for the wrong extruder:

Any thought though as to why it's triggering for the wrong tool? That's my real concern here.

What exactly do you mean by wrong tool? What have you put in which tool change file?

adammhaile · 5 Apr 2022, 11:31

@phaedrux said in Filament sensor triggers for the wrong extruder:

What exactly do you mean by wrong tool? What have you put in which tool change file?

When the filament sensor configured for T1 triggers, I get the following error:

Error: Filament error on extruder 0: noFilament

Which is the same error I get when the sensor for T0 triggers. I would expect the error for T1 to be:

Error: Filament error on extruder 1: noFilament

The T1 filament error also triggers filament-error0.g instead of filament-error1.g

tpost0.g contains M591 D0 S1
tpost1.g contains M591 D1 S1

I call M591 D<tool_id> S0 in the tfree files.

Phaedrux · 5 Apr 2022, 18:55

Can you please post your full set of files, including these macros

; set base tool names
M98 P"tools/t0.g" 
M98 P"tools/t1.g"
 
; load variable tool configs
M98 P"tools/setup.g"
 
; Ensure T0 loaded
M98 P"soft_load_tool.g" S0

adammhaile · 5 Apr 2022, 23:58

@phaedrux said in Filament sensor triggers for the wrong extruder:

Can you please post your full set of files, including these macros

Sure thing, everything can be viewed here: https://github.com/adammhaile/Rancor/tree/f48014f7924d1a6958722ad6c128a8c379bcafbb/sd/sys

The tools/ stuff is a little convoluted, but I'll try to explain best I can:

My machine is IDEX but has cold-swappable tool heads. I have 5 total tool heads that can be placed on either of the 2 tool carriages. So everything under tools/ is my attempt to create a management system for quickly swapping configs.

tools/t0.g and tools/t1.g simply just set a global variable with the name of the tool that is in that position. That name is then used to load configs from the correct directory under tools/. For the most part those configs set more global vars.

tools/setup.g takes all the currently set global vars and sets things like tool offsets.

soft_load_tool.g is basically just an extension of calling T<num> P0 because when a tool change happens I need it to also push a tool name into global.cur_tool which normally would happen in the tpost scripts. global.cur_tool is mostly used for filament handling because I have it setup so that I can have different filament configs based on the tool that is loaded.

Phaedrux · 14 Apr 2022, 05:37

Best I can figure there is an error in your tool files, but I can't spot it.

dc42 · 25 Apr 2022, 09:29

@adammhaile I confirm there is a bug. When the filament-error event is constructed, the CAN address and device number parameters are swapped.

I have fixed this in the source code. The fix will be in RRF 3.5.0beta1 and also in 3.4.1 if we do that release.

adammhaile · 25 Apr 2022, 11:21

@dc42 said in Filament sensor triggers for the wrong extruder:

@adammhaile I confirm there is a bug. When the filament-error event is constructed, the CAN address and device number parameters are swapped.
I have fixed this in the source code. The fix will be in RRF 3.5.0beta1 and also in 3.4.1 if we do that release.

Awesome. Thanks for the update!