3.5.0rc1: Input shaping causes layer shifts!?

[T3P3Tony]

@NeoDue

Github issue:
https://github.com/Duet3D/RepRapFirmware/issues/945

T3P3 created this issue 15 Jan 2024, 11:54 in Duet3D/RepRapFirmware

closed IS triggered Layer shifts in 3.5rc1+ #945

[dc42]

@NeoDue and @skrotz please can you both try the firmware at https://www.dropbox.com/scl/fo/8mwsfwo61tacbyxsu39j9/h?rlkey=zwyd8luhpj7hnanldm4rzm5om&dl=0. If you encounter any layer shifts, then to help me track down the cause please report the following:

• A M122 report taken after layer shifts have occurred. Don't run M122 more than once unless further layer shifts occur, because each time M122 is run it clears the data it reports, and I want the data that may relate to a layer shift.
• Your config.g file
• What M593 input shaping command you were using, if it isn't in the config.g file
• What height the layer shift(s) occurred at
• A link to the GCode file you were printing.

Also please verify that you don't get layer shifts if you do the same print with input shaping disabled (i.e. M593 P"none").

[NeoDue]

@dc42 thanks! I might only be able to do that the coming weekend, but I definitely will as soon as I can!

[vaike_peeter]

@dc42

Made test print with your rc2+ firmware. Layer shifted at 16,05mm

I didn't get M122 directly after layer shift, I did it when I disovered it.

M122 toolhead

M122 B121
Diagnostics for board 121:
Duet TOOL1LC rev 1.1 or later firmware version 3.5.0-rc.2 (2023-12-14 08:58:51)
Bootloader ID: SAMC21 bootloader version 2.8 (2023-07-25)
All averaging filters OK
Never used RAM 2672, free system stack 89 words
Tasks: Move(3,nWait,1.6%,71) HEAT(2,nWait,6.4%,91) CanAsync(5,nWait,0.0%,54) CanRecv(3,nWait,0.6%,77) CanClock(5,nWait,0.4%,67) ACCEL(3,nWait,0.0%,17) TMC(2,nWait,61.9%,57) MAIN(1,running,86.2%,316) IDLE(0,ready,0.0%,27) AIN(2,delaying,92.7%,114), total 249.8%
Last reset 21:44:27 ago, cause: software
Last software reset time unknown, reason: OutOfMemory, available RAM 16088, slot 0
Software reset code 0x01c0 ICSR 0x00000000 SP 0x20002770 Task MAIN Freestk 784 ok
Stack: 00004000 00005e8b 00004000 000041cf a5a5a5a5 00004000 a5a5a5a5 a5a5a5a5 a5a5a5a5 0001d199 a5a5a5a5 0001d1b5 a5a5a5a5 00005a4f a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5 a5a5a5a5
Driver 0: pos 0, 617.6 steps/mm, ok, SG min 0, read errors 2, write errors 1, ifcnt 144, reads 54569, writes 16, timeouts 140, DMA errors 0, CC errors 0, failedOp 0x71, steps req 0 done 15440450
Moves scheduled 261208, completed 261207, in progress 1, hiccups 4282, segs 40, step errors 0, maxLate 1 maxPrep 564, maxOverdue 5374, maxInc 2158, mcErrs 0, gcmErrs 0, ebfmin -1.00 max 1.00
Peak sync jitter -6/8, peak Rx sync delay 260, resyncs 0/0, no timer interrupt scheduled
VIN voltage: min 24.2, current 24.4, max 29.8
MCU temperature: min 28.9C, current 75.1C, max 75.2C
Last sensors broadcast 0x00001002 found 2 241 ticks ago, 0 ordering errs, loop time 0
CAN messages queued 1568794, send timeouts 6, received 969293, lost 0, errs 34187, boc 0, free buffers 18, min 17, error reg 110000
Last cancelled message type 4525 dest 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 420, adv 35575/74660
Accelerometer: LIS3DH, status: 00
Inductive sensor: not found
I2C bus errors 0, naks 6, contentions 0, other errors 0

M122 Mainboard

M122
=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.5.0-rc.2+ (2024-01-15 11:56:10) running on Duet 3 Mini5plus Ethernet (standalone mode)
Board ID: KHLQ8-GU8LU-F65J0-409N2-1313Z-H6T1G
Used output buffers: 8 of 40 (32 max)
=== RTOS ===
Static ram: 103168
Dynamic ram: 116132 of which 16 recycled
Never used RAM 18404, free system stack 128 words
Tasks: NETWORK(1,ready,23.0%,173) ETHERNET(5,nWait 7,0.2%,569) HEAT(3,nWait 6,0.7%,326) Move(4,nWait 6,6.8%,241) CanReceiv(6,nWait 1,1.0%,774) CanSender(5,nWait 7,0.2%,327) CanClock(7,delaying,0.1%,348) TMC(4,nWait 6,15.4%,66) MAIN(1,running,35.8%,667) IDLE(0,ready,0.0%,30) AIN(4,delaying,16.6%,256), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 21:45:00 ago, cause: software
Last software reset at 2024-01-15 21:55, reason: User, Gcodes spinning, available RAM 27976, slot 2
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x00000000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU revision 3, ADC conversions started 78301312, completed 78301310, timed out 0, errs 0
MCU temperature: min 17.7, current 33.9, max 34.4
Supply voltage: min 23.7, current 23.8, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/3, heap memory allocated/used/recyclable 2048/1296/1220, gc cycles 0
Events: 1 queued, 1 completed
Driver 0: ok, SG min 0, read errors 0, write errors 1, ifcnt 196, reads 57358, writes 25, timeouts 0, DMA errors 0, CC errors 0
Driver 1: ok, SG min 0, read errors 0, write errors 1, ifcnt 196, reads 57358, writes 25, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 39, reads 57352, writes 30, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 38, reads 57352, writes 30, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 37, reads 57353, writes 30, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
Date/time: 2024-01-16 19:51:08
Cache data hit count 4294967295
Slowest loop: 258.21ms; fastest: 0.11ms
=== Storage ===
Free file entries: 18
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 4.8ms, write time 10.9ms, max retries 0
=== Move ===
DMs created 83, segments created 35, maxWait 68167851ms, bed compensation in use: none, height map offset 0.000, max steps late 1, ebfmin 0.00, ebfmax 0.00
next step interrupt due in 35 ticks, enabled
Moves shaped first try 9805, on retry 12276, too short 53284, wrong shape 153332, maybepossible 8084
=== DDARing 0 ===
Scheduled moves 281191, completed 281158, hiccups 0, stepErrors 0, LaErrors 211, Underruns [0, 0, 5], CDDA state 3
=== DDARing 1 ===
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 9 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.5
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is doing "G1 X220.349 Y71.367 E.00382" 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
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is doing "M0" in state(s) 0, sync state 1
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x0000807
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 970855, received 1569669, lost 0, errs 1, boc 0
Longest wait 5ms for reply type 4014, peak Tx sync delay 420, free buffers 26 (min 24), ts 391502/391501/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 230.49ms; fastest: 0.03ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 1 of 8
= Ethernet =
Interface state: active
Error counts: 0 0 9158 0 0 0
Socket states: 5 2 2 2 2 2 0 0
 

config.g

; Configuration file for Duet 3 Mini 5+ (firmware version 3.5)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v3.3.16 on Thu Nov 23 2023 20:11:54 GMT+0200 (Eastern European Standard Time)
 
; General preferences
M575 P1 S1 B57600                                ; enable support for PanelDue
G90                                              ; send absolute coordinates...
M83                                              ; ...but relative extruder moves
M550 P"VT1011"                                   ; set printer name
M669 K1                                          ; select CoreXY mode
 
; Wait a moment for the CAN expansion boards to start
G4 S2
 
; Network
M552 P192.168.90.200 S1                          ; enable network and set IP address
M553 P255.255.255.0                              ; set netmask
M554 P192.168.90.1                               ; set gateway
M586 P0 S1                                       ; enable HTTP
M586 P1 S1                                       ; enable FTP
M586 P2 S0                                       ; disable Telnet
 
;          --- Drive map ---
; (While looking at the printer top down)
 
;             0.0-----0.1
;              |  0.2  |
;              |-------|
;              |0.3|0.4|
;               ---+---
;                Front
 
; Drives for X & Y
M569 P0.0 S1 D2                                    ; physical drive 0.0 goes forwards
M569 P0.1 S1 D2                                    ; physical drive 0.1 goes forwards
 
; Drives for Z
M569 P0.2 S0 D3                                     ; physical drive 0.2 goes backwards Stealthchop  | Z1
M569 P0.3 S0 D3                                    ; physical drive 0.3 goes backwards Stealthchop  | Z0
M569 P0.4 S0 D3                                    ; physical drive 0.4 goes backwards Stealthchop  | Z2
 
; Drive for Extruder 
M569 P121.0 S0 D2                                   ; physical drive 121.0 goes backwards
 
; Motor mapping and steps per mm
M584 X0.0 Y0.1 Z0.3:0.2:0.4 E121.0               ; set drive mapping
M350 X16 Y16 Z16 E16 I1                          ; configure microstepping with interpolation
M92 X160 Y160 Z800                               ; set steps per mm
M92 E617.6470588                                 ; galileo 2 steps per mm
 
; Drive currents
M906 X1700 Y1700 Z1000 E700 I30                   ; set motor currents (mA) and motor idle factor in per cent
M84 X Y Z E0 S30                                 ; Set idle timeout
 
; Axis accelerations and speeds
M566 X500 Y500 Z120 E300 P1                       ; set maximum instantaneous speed changes (mm/min)
M203 X18000 Y18000 Z900 E7200                    ; set maximum speeds (mm/min)
M201 X8000 Y8000.00 Z350 E2000                    ; set accelerations (mm/s^2)
 
; Reduced accelerations
;M201.1 X500 Y500 Z80 E500                        ; Set reduced acceleration for special move types (mm/s²)
 
; Printing and travel accelerations
M204 P5000 T7000                                 ; Set printing acceleration and travel accelerations (mm/s²)
 
 
; Axis Limits
M208 X0 Y0 Z0 S1                                  ; set axis minimal
 
M208 X300 Y305 Z240 S0                           ; set axis maximal
 
; Endstops
M574 X2 S1 P"121.io1.in"                         ; configure sensorless endstop for high end on X
M574 Y2 S1 P"io6.in"                             ; configure sensorless endstop for high end on Y
 
; Klicky
M558 P8 C"^121.io2.in" T18000 F600:180 H2 A10 S0.01   ; set Z probe type to KLICKY and the dive height + speeds
G31 P500 X0 Y28 Z4.80                            ; 5,4 set Z probe trigger value, offset and trigger height(Z_offset - bigger number bed closer to nozzle)
 
; Bed leveling
M671 X-50:150:350 Y18:348:18 S5                  ; front left, back, front right
M557 X15:285 Y30:285 P5                         ; define grid for mesh bed compensation, bed mesh distance 83mm to get 4x4 square
 
; Accelerometer
M955 P121.0 I10                                  ; Configure accelerometer
M593 P"mzv" F25 S0.01 L0.15                           ; disabled 3.5.0rc1 has layer shift issues when IS enabled
 
; Heaters
; Bed heater
M308 S0 P"temp0" Y"thermistor" T100000 B4725 C7.06e-8 A"Bed" ; 4138 configure sensor 0 as thermistor on pin temp0
M950 H0 C"out0" T0                               ; create bed heater output on out0 and map it to sensor 0
M307 H0 B0 S1.00                                 ; disable 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
M143 H0 A2 C0 S120                               ; Make sure bed heater stays below 120C
M143 H0 A1 C0 S125                               ; Make sure bed heater shuts down at 125C
 
; Hodend heater
M308 S1 P"121.temp0" Y"pt1000" A"Hotend"         ; configure sensor 1 as thermistor on pin 121.temp0
M950 H1 C"121.out0" T1                           ; create nozzle heater output on 121.out0 and map it to sensor 1
M307 H1 B0 S1.00                                 ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S350                                     ; set temperature limit for heater 1 to 350C
 
 
; Chamber heater
M308 S9 P"temp1" Y"thermistor" A"Chamber" T100000 B4725 C7.06e-8 ; Chamber thermistor conf - ATC Semitec 104NT-4-R025H42G
M950 H9 C"io5.in" Q1 T9                           ; dummy port used
M307 H9 B0 S1.00
M141 H9 ; fake chamber heater for reporting in DWC
M143 H9 P0 S40 A2
M143 H9 P1 S60
 
; Duet5+ mcu temp
M308 S3 Y"mcu-temp" A"MCU"                       ; Configure sensor 2 as MCU temperature
M912 P0 S-2.9                                    ; MCU temp calibration parameters
 
; toolhead temp
M308 S12 Y"mcu-temp" P"121.dummy" A"1LC MCU"
 
; Fans
;Part cooling
M950 F0 C"121.out1"                              ; create fan 0 on pin 121.out1 and set its frequency
M106 P0 S0 H-1 C"Part Cooling"                   ; set fan 0 value. Thermostatic control is turned off
 
;Hotend fan
M950 F1 C"121.out2"                              ; create fan 1 on pin 121.out2 and set its frequency
M106 P1 S1 H1 T45 C"Hotend Fan"                  ; set fan 1 value. Thermostatic control is turned on
 
; Bed fan
M950 F2 C"out3"                                  ; create fan 2 on pin out3 and set its frequency
M106 P2 C"BEDF_12V" S0 H-1                       ; set fan 2 value. Thermostatic control is turned on
 
; Exhaust fan
M950 F3 C"out6"                                  ; create fan 3 on pin out6 and set its frequency
M106 P3 C"EXHAUSTF" S0 B0.1 H9 T45               ; set fan 3 value. Thermostatic control is turned on
 
; Nevermore filter
M950 F4 C"out5"                                  ; create fan 4 on pin out5 and set its frequency
M106 P4 C"FILTER" S0 B0.1 H0 T90                 ; set fan 4 value. Thermostatic control is turned on
 
; Tools
M563 P0 S"Mosquito Magnum" D0 H1 F0              ; define tool 0
G10 P0 X0 Y0 Z0                                  ; set tool 0 axis offsets
G10 P0 R0 S0                                     ; set initial tool 0 active and standby temperatures to 0C
 
; Custom settings are not defined
 
; Miscellaneous
M950 P0 C"out1"                                  ; Create output Port0 attached to out1 connector for LED lights
M501                                             ; load saved parameters from non-volatile memory
T0                                               ; select first tool

Print file 3DBenchy-Voron-Trident-300-0.4-nozzle-1011-ABS-Orange-Polymaker.gcode

Active IS graph IS

[oliof]

@vaike_peeter do you have a spec sheet of your stepper drivers at hand?

[vaike_peeter]

@oliof

Z-motors - LDO-42STH40-1684L300E

A and B(x,y) motors - LDO-42STH48-2004MAH

I already checked current if you think that.

[oliof]

@vaike_peeter with your .9 degree steppers you hit like 48kHz step rate per axis on CoreXY with 16x microstepping. You should get fine prints dropping down to 8x microstepping and giving more headroom for additional computation like IS.

There are some other considerations like maximum RPM and torque that you may be hitting with the 2004s. Check the back emf calculator and the TDS of your steppers for the physical stepper limits too. https://www.reprapfirmware.org/emf.html

[vaike_peeter]

@oliof
I will test this when I get back home

[benecito]

FYI had something similar happen this night on a machine running just closed loop motors.

Just installed the RC2+ and will see if it happens again.
Already sent this to @dc42 directly as well.

[NeoDue]

@dc42 just to make sure since I have no experience yet with the test firmware versions you provide: On my 6HC with no further addon electronics than the PanelDue (a clone, as already noted somewhere here in the forum, since the original PanelDue has too large footprint for this printer - I would have used the one I already own otherwise) and the Wifi module I just need to upload and install Duet3Firmware_MB6HC.bin - correct?

[droftarts]

@NeoDue said in 3.5.0rc1: Input shaping causes layer shifts!?:

I just need to upload and install Duet3Firmware_MB6HC.bin - correct?

Correct!

Ian

[vaike_peeter]

@oliof That was really good hint. My test print came out without layer shift. Will continue testing but seems promising. Thank you.
Now X and Y motors are configured 8 microsteping with 80 steps per mm.

[NeoDue]

@droftarts thanks! But I fear I need to report that did not work as intended at all - the last information I got from the DWC was that it was updating the board firmware... and now I am having a dead printer. I fear I need to work my way to the Duet in the printer and do a restore via USB this weekend instead of doing the test. Now where was the website explaining that process, it has been ages since I needed that...

[droftarts]

@NeoDue Oh dear, sorry! Maybe your iap file was out of date?

USB firmware flashing: https://docs.duet3d.com/User_manual/RepRapFirmware/Updating_firmware

Ian

[NeoDue]

@droftarts The one that was in the Duet was suitable to update from 3.5.0 beta4 to rc1 and then to rc2. Do I need another one for the test version? There is none in the dropbox folder...

[droftarts]

@NeoDue No, that was probably the latest. Looks like it hasn't been updated for a couple of years: https://github.com/Duet3D/DuetIAP

Sorry, not sure why your update failed. Is the DIAG light glowing? See https://docs.duet3d.com/en/User_manual/Troubleshooting/Duet_wont_respond for troubleshooting, just in case it is recoverable.

Ian

[NeoDue]

@droftarts Thanks for the links! I will check that. But for now there is a little mechanical work needed - the Snapmaker J1 has its electronics compartment in the base, and I need to remove the housing windows and screw up the z axis before I can unscrew and lift the metal plate covering it... quite some screws before I can see the Duet again

[NeoDue]

@droftarts Edit: I just managed to catch a glimpse through an unused former USB port opening. If I saw correctly from the reflection, the four voltage LEDs are active, but that's about it. But as noted above, I need to take open the compartment to get a clear look.

[dc42]

@vaike_peeter thanks for the data. How confident are you that if you disable input shaping, you can do the same print at the same speed without getting any layer shifting?

[vaike_peeter]

@dc42 I will do teat print with IS disabled and then post results. I modified my config for x and y steppers and changed print external perimeter accel to 2000 because of ringing. Defaul accel is 5k. I’m off my printer right now.