[RRF 3.5.2] Extruder motor fails to do a long extrusion

leone

Hi all,

I tested on MB6HC+TOOL1LC with RRF 3.5.2 a very long extrusion move (G1 E20000 F100) but the extruder is not able to do it successfully. It starts but it seems to be stuck or losing steps (see video attached).

20240806_204658.mp4

In another setup, I have also the extruder connected to the mainboard (Mini5+) and the same command runs properly.

Does anyone have an explanation for that? It seems related to the CAN communication.

Thank you all in advance.

deckingman

@leone On the video you posted, it looks to me like the extruder is trying to run very much faster than 100mm/minute. My best guess is that either you miss typed the feedrate or you have the steps per wildly out. Posting your config.g as well some information about the extruder and motor would be helpful.

adambx

@deckingman I am working with @leone on this:

There was no typo, having (G1 E20 F100) works fine and the extruder moves with proper F100

20240806_204614.mp4

Here you can see the rotation speed in the first few seconds and the console line later.
In the first Video you can see the console input in the beginning. The only change is the E parameter value.

MB6HC, TB1LC. I can post the extruder config later when i have access to it, but it has been running fine for the last couple of years. Although we have never extruded 20m at once and only discovered this by accident

Cheers

adambx

So here with a little better production value, and full config

I noticed I had 128 Microstepping configured for the extruder, which seemed a little excessive, so i reduced it down to 32, to see if the issue still occurs. This time the extruder emitted a loud screeching noise without motor movement .(beware of the volume when watching the video) I've attached a random coupling to the output shaft just for better visualization of the movement.

You can see the console as well as the extruder in the video with both E20 and E20000 variants.
WhatsApp Video 2024-08-07 at 20.58.56_bf3ab18c.mp4

Note that the issue occurs in both Standalone and SBC mode when the extruder is connected via CAN.

Full config.g

; General preferences
G90                                          ; send absolute coordinates...
M83                                          ; ...but relative extruder moves
M550 P"duet3"                               ; set printer name

; Drives
M569 P0 S1 D3                            
M569 P1 S1 D3                                
M569 P2 S1 D3                                
M569 P3 S1 D3                                
M569 P4 S1 D3	
M569 P121.0 S0 

M584 X0 Y4:3 Z1:2 E121.0

;spindle XY 50mm/r
;spindle Z 5mm/r
;extruder 30.778125/r Bondtech QR
M350 X128 Y128 Z32 E32 I1                      ; configure microstepping with interpolation
M92  X512.00 Y512.00 Z17920 E1408.4125             ; set steps per mm
M566 X1000 Y1000 Z10.00 E600.00                 ; set maximum instantaneous speed changes (mm/min)
M203 X30000.00 Y30000.00 Z300.00 E1200.00       ; set maximum speeds (mm/min)
M201 X2500.00 Y2500.00 Z50.00 E3000.00          ; set accelerations (mm/s^2)
M906 X1400 Y1400 Z650 E1000 I30                 ; set motor currents (mA) and motor idle factor in per cent
M84 S30                                         ; Set idle timeout

; ringing cancellation 24Hz
M593 P"zvd" F40.5
M572 D0 S0.02

; Axis Limits
M208 X-55 Y-20 Z0 S1
M208 X440 Y400 Z300 S0

; Endstops
M574 X1 S1 P"!io0.in"
M574 Y1 S1 P"!io1.in+!io2.in"
M574 Z1 S1 P"!io7.in+!io8.in"

; Z-Probe1
M558 K0 P1 C"!io4.in" H2 F1500
G31 K0 P500 X0 Y0 Z-0.1

M557 X-10:320 Y63:230 P5:3                   ; define mesh grid

G4 S2 ; wait for expansion boards to start
; Heaters
M308 S0 P"temp2" Y"thermistor" T100000 B4138 ; configure sensor 0 as thermistor on pin temp0
M950 H0 C"out2" T0 Q10                          ; create bed heater output on out0 and map it to sensor 0
M143 H0 S110                                 ; set temperature limit for heater 0 to 120C
M307 H0 R0.244 K0.145:0.000 D18.04 E1.35 S1.00 B0
M140 H0                                      ; map heated bed to heater 0
M308 S1 P"121.temp0" Y"pt1000" ; configure sensor 1 as thermistor on pin temp2
M950 H1 C"121.out0" T1                           ; create nozzle heater output on out1 and map it to sensor 1
M143 H1 S280                                 ; set temperature limit for heater 1 to 280C
M307 H1 B0 S1.00                             ; disable bang-bang mode for heater  and set PWM limit

; Heater model parameters
M307 H1 R1.947 K0.240:0.254 D11.64 E1.35 S1.00 B0 V23.4

; Fans
M950 F0 C"121.out1" Q500                         ; create fan 0 on pin out3 and set its frequency
M106 P0 S0 C"T0 Hotend"                               ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"121.out2"                         ; create fan 1 on pin out4 and set its frequency
M106 P1 C"T0 Coldend" H1:1 T40                             ; Coldend on for extruder > 40 C
M950 F9 C"out9"
M106 P9 S200 C"UV Led"
M950 F8 C"!out4"
M106 P8 S80 I1 C"Cabinet"

M591 D0 P3 C"121.io1.in" S1 R92:110 L25.6  ; filament monitor
M591 D0 ; display filament sensor parameters for extruder drive 0

; Tools
M563 P0 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

M200 D2.85
M200 S0

dc42

@adambx the maximum duration of a move that RRF can handle is about 47 minutes on Duet 3 (which is 2^31 cycles of the 750kHz clock) and 38 minutes on Duet 2. Your move would take 200 minutes. Feel free to log an issue on Github about this. Meanwhile, I suggest you split your G1 command into several commands each taking no more than about 30 minutes.

This isn't specific to moves sent to CAN-connected drives, although when you exceed this limit the symptom may be different for locally-connected drives.

adambx

@dc42 understood, thanks for the detailed response. Moves this long are not really a use case when 3d printing i guess. Certainly not important for us right now as the behaviour was only noticed on accident.

Thanks again!
Cheers