Duet2 WiFi generating polygons instead of circles

[Phaedrux]

Is your post processor generating G2 arcs?
Firmware version?

[T3P3Tony]

@flopes please try and reply here again

[flopes]

@Phaedrux
Hi
It seems I was not fully registered yet. Now I can reply

I have firmware version 3 on the board

Using cartesian machine.

Everything works fine for larger features, but does not work ok for small features as described
Please help
Thnaks

[droftarts]

@flopes please post your config.g and the response to M122. Without some information it is difficult to diagnose where the problem might be.

Ian

[T3P3Tony]

@flopes also please post a section for the gcode with the features that are being output incorrectly in it (not the whole file!)

[flopes]

@droftarts This is the M122
m122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 3.4.4 (2022-10-20 16:17:41) running on Duet WiFi 1.02 or later
Board ID: 0JD0M-9X6JA-JUNSS-6JKDJ-3SD6J-T9KRU
Used output buffers: 3 of 26 (26 max)
=== RTOS ===
Static ram: 23860
Dynamic ram: 75720 of which 0 recycled
Never used RAM 12356, free system stack 104 words
Tasks: LASER(notifyWait,0.6%,38) NETWORK(notifyWait,193.4%,231) HEAT(notifyWait,1.9%,324) Move(notifyWait,145.5%,294) MAIN(running,152.1%,410) IDLE(ready,12.4%,30), total 505.9%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 90:58:49 ago, cause: software
Last software reset at 2023-03-17 12:46, reason: User, GCodes spinning, available RAM 12312, slot 1
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00417000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x0c
Aux0 errors 0,0,0
Step timer max interval 0
MCU temperature: min 33.9, current 35.0, max 44.4
Supply voltage: min 19.5, current 19.8, max 20.1, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 0/0, heap memory allocated/used/recyclable 0/0/0, gc cycles 0
Events: 0 queued, 0 completed
Driver 0: standstill, SG min 0
Driver 1: standstill, SG min 0
Driver 2: standstill, SG min 0
Driver 3: standstill, SG min n/a
Driver 4: standstill, SG min n/a
Driver 5:
Driver 6:
Driver 7:
Driver 8:
Driver 9:
Driver 10:
Driver 11:
Date/time: 2023-03-21 07:45:41
Cache data hit count 4294967295
Slowest loop: 17.15ms; fastest: 0.11ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Storage ===
Free file entries: 10
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest read time 9.6ms, write time 152.0ms, max retries 0
=== Move ===
DMs created 83, segments created 6, maxWait 366518ms, bed compensation in use: none, comp offset 0.000
=== MainDDARing ===
Scheduled moves 1214398, completed 1214398, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 21], CDDA state -1
=== AuxDDARing ===
Scheduled moves 0, completed 0, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== GCodes ===
Segments left: 0
Movement lock held by null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
Daemon is idle in state(s) 0
Autopause is idle in state(s) 0
Code queue is empty
=== Network ===
Slowest loop: 175.88ms; fastest: 0.00ms
Responder states: HTTP(2) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
= WiFi =
Network state is active
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 1
WiFi firmware version 1.27
WiFi MAC address 48:3f:da:a6:ee:bb
WiFi Vcc 3.46, reset reason Power up
WiFi flash size 2097152, free heap 22296
WiFi IP address 192.168.10.76
WiFi signal strength -65dBm, mode 802.11n, reconnections 0, sleep mode modem
Clock register 00002002
Socket states: 0 0 0 0 0 0 0 0

[flopes]

@droftarts This is the config.g
; Configuration file for Duet WiFi (firmware version 3)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.16 on Fri Mar 17 2023 12:42:29 GMT-0700 (Pacific Daylight Time)

; General preferences
M575 P1 S1 B57600 ; enable support for PanelDue
G90 ; send absolute coordinates...
M83 ; ...but relative extruder moves
M550 P"Laser Cutter" ; set printer name

; Network
M552 S1 ; enable network
M586 P0 S1 ; enable HTTP
M586 P1 S0 ; disable FTP
M586 P2 S0 ; disable Telnet

; Drives
M569 P0 S1 ; physical drive 0 goes forwards
M569 P1 S0 ; physical drive 1 goes backwards
M569 P2 S1 ; physical drive 2 goes forwards
M569 P3 S1 ; physical drive 3 goes forwards
M584 X0 Y1 Z2 E3 ; set drive mapping
M350 X8 Y8 Z8 E8 I0 ; configure microstepping without interpolation
M92 X160.00 Y160.00 Z160.00 E1.00 ; set steps per mm
M566 X60.00 Y60.00 Z60.00 E6.00 ; set maximum instantaneous speed changes (mm/min)
M203 X6600.00 Y6600.00 Z6600.00 E6.00 ; set maximum speeds (mm/min)
M201 X10.00 Y10.00 Z10.00 E1.00 ; set accelerations (mm/s^2)
M906 X1000 Y1000 Z1000 E300 I30 ; set motor currents (mA) and motor idle factor in per cent
M84 S1 ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z-200 S1 ; set axis minima
M208 X1100 Y1100 Z755.2 S0 ; set axis maxima

; Endstops
M574 X2 S1 P"!^xstop" ; configure switch-type (e.g. microswitch) endstop for high end on X via pin !^xstop
M574 Y1 S1 P"!^ystop" ; configure switch-type (e.g. microswitch) endstop for low end on Y via pin !^ystop
M574 Z2 S1 P"!^zstop" ; configure switch-type (e.g. microswitch) endstop for high end on Z via pin !^zstop

; Z-Probe
M558 P0 H0 F120 T6000 ; disable Z probe but set dive height, probe speed and travel speed
M557 X5:100 Y5:100 S5 ; define mesh grid

; Heaters
M308 S0 P"bedtemp" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin bedtemp
M950 H0 C"bedheat" T0 ; create bed heater output on bedheat and map it to sensor 0
M307 H0 B1 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
M308 S1 P"e0temp" Y"thermistor" T100000 B4138 ; configure sensor 1 as thermistor on pin e0temp
M950 H1 C"e0heat" T1 ; create nozzle heater output on e0heat and map it to sensor 1
M307 H1 B0 S1.00 ; disable bang-bang mode for heater and set PWM limit
M143 H1 S280 ; set temperature limit for heater 1 to 280C

; Fans
M950 F0 C"fan0" Q500 ; create fan 0 on pin fan0 and set its frequency
M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"fan1" Q500 ; create fan 1 on pin fan1 and set its frequency
M106 P1 S1 H-1 ; set fan 1 value. Thermostatic control is turned off

; Tools
M563 P0 S"Z Pogo" D0 H1 F0 ; define tool 0
G10 P0 X5 Y5 Z5 ; set tool 0 axis offsets
G10 P0 R0 S0 ; set initial tool 0 active and standby temperatures to 0C
M563 P1 S"Laser" F0 ; define tool 1
G10 P1 X0 Y0 Z0 ; set tool 1 axis offsets
G10 P1 R0 S0 ; set initial tool 1 active and standby temperatures to 0C

; Custom settings are not defined

; Miscellaneous
M501 ; load saved parameters from non-volatile memory
M911 S10 R11 P"M913 X0 Y0 G91 M83 G1 Z3 E-5 F1000" ; set voltage thresholds and actions to run on power loss

[flopes]

@flopes This is actually the config.g when I enlarged the part 10x and tricked my printer to print 10x smaller with success.

[flopes]

@flopes This is the g code that fails:
....
G01 Z0 F6.
G01 X.087 Y-.064 Z0 F4.
G03 X.087 Y.064 Z0 I0 J.064 F4.
G01 X0 Y.064 Z0 F4.
G03 X0 Y-.064 Z0 I0 J-.064 F4.
G01 X.043 Y-.064 Z0 F4.
.....

[dc42]

@flopes the minimum length for segments that make up arcs is currently set at 0.1mm. We should perhaps revise that value for situations with high steps/mm, low feed rates and small arc radius.

[flopes]

@dc42

Hi
Is there a quick fix, or something easily changeable in the firmware to get to produce arches of 5microns?
My printer is only 10cm by 10cm so I don't mind sacrificing the maximum length if that means increasing resolution
Thanks

[flopes]

@flopes The first obround is 100micron tall by 300 wide

[flopes]

@flopes Our feed is 6mm/min!

[flopes]

@flopes Also there is some uncertainty on the position of some features of about 25micron.
We cut panels with 100 devices like this

[flopes]

@flopes Some features are aligned most of time. IT IS NOT STEPPER MISSING STEPS.

[flopes]

@flopes Most devices cut like this
Any help on the matter would be greatly appreciated

[T3P3Tony]

@flopes one option to try would be to setup the config as if the printer was 10* bigger, then set the microstepping to 64 instead of 8, and the steps/mm to an appropriately adjusted value. The idea being that the limit of 0.1mm segments would then be 0.01mm in reality due to the 10x scaling.

[flopes]

@T3P3Tony
Scaling 10:1 is how I have been operating. Do you know what is the minimum positioning resolution of the Duet2?
I know It responds to G21G91G1X0.001 with 1 micron displacement, but would the motion control allow for such fine positioning? Could I laser drill a grid 5micron by 5micron?

My tests show about 25micron uncertainty on the position of a cut, but once the cut starts, it can be very precise (5micron?)

[T3P3Tony]

@flopes you are limited by the step resolution. If you have been operating at a 10:1 scaling then switch to a 100:1 as a work around for now.

[flopes]

@T3P3Tony Thanks. I will run a test