Clicking/thunking noise from motors on 3.6.0-rc.2

[Chorca]

So I recently upgraded to 3.6.0-rc2, and after the upgrade, I notice that the motors now click/thunk approx every 250ms. The motors are on EXP1HCL boards, and are not in closed loop mode, as I haven't been able to get that working right yet.
It does not appear to be skipping steps, and to validate that, I slowed the printing down to 20% or so, and by slowing down, the clicking gets quieter, but has the same ~250ms cadence. Speeding it up and slowing it down changes the volume but not the speed of the clicking. Rapid movements track correctly but the faster motion causes the clicks to be louder.
If needed I can take a video and post that.

I've included the config.g and the M122 output from all boards on the system:
M122.txt
config.g

[dc42]

@Chorca thanks for your report. All expansion boards send status information to the main board every 250ms, so yes there is something happening every 250ms.

Please can you downgrade the firmware on just the 1HCL boards to 3.6.0-rc.1 and check whether the clicking goes away. DWC will warn you about incompatible software versions but you can ignore that warning.

If 3.6.0-rc.1 doesn't show the problem, please try 3.6.0-rc.1+1 (again just on the 1HCL boards) which you can find at https://www.dropbox.com/scl/fo/0xdvvzgqfrs5abyk75ss8/AL3i6s7z9UacEGYsxiR7pXw?rlkey=xpm61w2jlyqlawwjzy4zsq2lt&dl=0. And if that doesn't show the problem, 3.6.0-rc.1+2 from https://www.dropbox.com/scl/fo/y03luwmbypirbxncla3rk/AAJFLPFsVdFylemyhkXsAac?rlkey=7cq4svp4rzl2ztdffpzq2ghjk&dl=0 and 3.6.0-rc.1+3 from https://www.dropbox.com/scl/fo/geqmn8gbn97n6b587mkbk/AJ2hBIqO-L57_QpR_uqHJ9c?rlkey=fw37wycbp2gil8rvxhe7aopy7&dl=0.

[Chorca]

3.6.0-rc.1 has the issue, so I went back further and re-verified the 3.5.4 did not have the issue. From there I upgraded to 3.6.0-beta.1 but that did not successfully install, so I went to 3.6.0-beta.2 and that did install, and has the issue.

[dc42]

@Chorca thanks for the information. I will investigate.

[dc42]

@Chorca do you have a daemon.g file present? If so, please post it here.

[Chorca]

@dc42 I don't see one in the list of system files, I don't think I have one.

[dc42]

@Chorca I wasn't able to reproduce the issue you reported, but by looking at your M122 reports I believe I have identified the cause, which I have fixed. Please try the 3.6.0-rc.2+4 firmware at https://www.dropbox.com/scl/fo/tayuteu4qy46yzn799mem/AMXF1iHCPWoQJpFHFECfRH8?rlkey=32q0r4djndboskdg3o59n0e00&dl=0.

Note, this build has received minimal testing, so use it with caution. You may wish to run with reduced motor currents until you have some experience with it.

[Chorca]

@dc42 I went and installed that version on all four boards and the noises stopped, even at high speeds there is no more thunking noises from the motors.

Thanks for the fix!

[dc42]

@Chorca thanks for confirming! The fix will be includ idn the next RC or 3.6.0 stable release.