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Extruder motor stops during print…

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  • undefined
    UltiBots
    last edited by 22 Dec 2017, 14:03

    The heater still shows active, with no error messages in the GCode Console.

    Going to swap extruders and test.

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    • undefined
      ofloveandhate
      last edited by 23 Jan 2018, 20:08

      OP here. d300vs with firmware RepRapFirmware for Duet Ethernet version 1.19.2 (2017-09-01), Duet Ethernet 1.0.

      repeated failures of the following kind:

      the extruder stops responding to moves, with no error message. only way to get it responsive is to M999 or power cycle.

      d300vs thread here: http://forum.ultibots.com/viewtopic.php?f=59&t=297

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      • undefined
        dc42 administrators
        last edited by 23 Jan 2018, 21:27

        I suggest you start by upgrading the firmware to 1.20. It provides better monitoring of the stepper drivers, so it may warn you if the driver is reporting an unusual status.

        If the issue recurs, after it has happened and before rebooting, please send M122 to get a diagnostic report. Also send M906 without any parameters and confirm that the current is still set correctly.

        Duet WiFi hardware designer and firmware engineer
        Please do not ask me for Duet support via PM or email, use the forum
        http://www.escher3d.com, https://miscsolutions.wordpress.com

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        • undefined
          ofloveandhate
          last edited by 23 Jan 2018, 21:33

          ok, thanks. will report back in a few days.

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          • undefined
            ofloveandhate
            last edited by 27 Jan 2018, 22:04

            another failure




            M906
            Motor current (mA) - X:1000, Y:1000, Z:1000, E:400:400:400:400:400:400:400:400:400, idle factor 30%
            
            
            M122
            === Diagnostics ===
            Used output buffers: 3 of 32 (9 max)
            === Platform ===
            RepRapFirmware for Duet Ethernet version 1.20 running on Duet Ethernet 1.0
            Board ID: 08DDM-9FAMU-JW4S4-6JKD8-3SD6L-TMXMS
            Static ram used: 11992
            Dynamic ram used: 98816
            Recycled dynamic ram: 3880
            Stack ram used: 1216 current, 8448 maximum
            Never used ram: 7936
            Last reset 27:23:06 ago, cause: power up
            Last software reset at 2018-01-26 12:31, reason: User, spinning module GCodes, available RAM 10464 bytes (slot 0)
            Software reset code 0x0003 HFSR 0x00000000, CFSR 0x00000000, ICSR 0x0441f000, BFAR 0xe000ed38, SP 0xffffffff
            Error status: 0
            Free file entries: 10
            SD card 0 detected, interface speed: 20.0MBytes/sec
            SD card longest block write time: 0.0ms
            MCU temperature: min 41.0, current 41.2, max 60.2
            Supply voltage: min 23.8, current 24.4, max 24.9, under voltage events: 0, over voltage events: 0
            Driver 0: standstill, SG min/max 0/1023
            Driver 1: standstill, SG min/max 0/1023
            Driver 2: standstill, SG min/max 0/1023
            Driver 3: standstill, SG min/max 0/1023
            Driver 4: standstill, SG min/max not available
            Date/time: 2018-01-27 15:56:14
            Cache data hit count 4294967295
            Slowest main loop (seconds): 0.607014; fastest: 0.000045
            === Move ===
            MaxReps: 5856, StepErrors: 0, FreeDm: 240, MinFreeDm 120, MaxWait: 2357420531ms, Underruns: 0, 1
            Scheduled moves: 0, completed moves: 0
            Bed compensation in use: none
            Bed probe heights: 0.000 0.000 0.000 0.000 0.000
            === Heat ===
            Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
            Heater 0 is on, I-accum = 0.0
            Heater 1 is on, I-accum = 0.5
            === GCodes ===
            Segments left: 0
            Stack records: 2 allocated, 0 in use
            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
            serial is idle in state(s) 0
            aux is idle in state(s) 0
            daemon is idle in state(s) 0
            queue is idle in state(s) 0
            autopause is idle in state(s) 0
            Code queue is empty.
            === Network ===
            State: 5
            HTTP sessions: 1 of 8
            Responder states: HTTP(1) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0)
            
            

            what should i try next? i have not yet tried the other extruder pins on my board. i also have a wifi i can try, but that's pretty invasive, and it makes connecting a PITA.

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            • undefined
              ofloveandhate
              last edited by 27 Jan 2018, 22:39

              ok, so i tried something. with the machine in its errored state, i swapped the extruder motor pins to E1, instead of E0. then, i made a new tool in the web interface.

              switching to the new tool on the other pins allowed me to extrude! then, as a sanity check, i swapped the pins back to E0, changed back to the original tool, and was unable to extrude. ok, i am not insane. switch to new tool on E1, extruding is ok.

              i think i will try printing on E1.

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              • undefined
                ofloveandhate
                last edited by 28 Jan 2018, 19:48

                i printed on E1 last night, to no avail. still failed. i am unable to connect to the printer, "due to the duet firmware". wish i had a screencap of the page – did a refresh, and now get nothing. i am unable to connect to the printer through any other means. my normal fallback of repetier host, simplify3d, and all other programs fail to connect.

                i have now wasted about two kg of plastic due to this problem...

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                • undefined
                  ofloveandhate
                  last edited by 29 Jan 2018, 14:58

                  so, i swapped boards to my wifi board, with firmware 1.19.2. another failure.

                  i updated on the wifi to 1.20, and am reprinting now.

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                  • undefined
                    ofloveandhate
                    last edited by 29 Jan 2018, 19:17

                    another failure, on my wifi, 1.20. we can safely say:

                    • either neither of my duet boards are defective, or both are

                    • if this is a firmware problem, it exists in 1.19.2 and 1.20

                    i additionally believe that

                    • we can rule out my wiring as a problem. otherwise, when i switched E0 to E1, the extruder would not have moved without a restart. however, if my wiring is causing this fault, it should be firmware detectable… ideally

                    one problem i have observed is that the firmware is unable to detect if the extruder motor comes disconnected. you can unplug, and replug, no errors. should this not be observable?

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                    • undefined
                      ofloveandhate
                      last edited by 29 Jan 2018, 22:57

                      is this the same problem as i am experiencing?

                      https://community.ultimaker.com/topic/4733-print-stops-or-fails-halfway-through/

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                      • undefined
                        ofloveandhate
                        last edited by 29 Jan 2018, 22:58

                        it seemed so at first, but no, my fans work fine. that post was about heat creep, not the motor stopping.

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                        • undefined
                          dc42 administrators
                          last edited by 29 Jan 2018, 23:20

                          Does extrusion stop at the same point in the print each time?

                          The stepper drivers on the Duet can in theory detect when a motor wire is disconnected, but in practice we found it gave false positives, so I disabled that facility. If I can find a way to filter out the false positives, I will enable it again.

                          Duet WiFi hardware designer and firmware engineer
                          Please do not ask me for Duet support via PM or email, use the forum
                          http://www.escher3d.com, https://miscsolutions.wordpress.com

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                          • undefined
                            ofloveandhate
                            last edited by 29 Jan 2018, 23:42

                            another thought i had – maybe i should put a fan on the duet? is the board overheating?

                            https://www.duet3d.com/wiki/Connecting_and_configuring_fans

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                            • undefined
                              ofloveandhate
                              last edited by 29 Jan 2018, 23:43

                              no, it is not the same point every time.

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                              • undefined
                                ofloveandhate
                                last edited by 29 Jan 2018, 23:45

                                here's a snippet of what my gcode looks like:

                                G1 X-9.773 Y20.202 E0.0240
                                G1 X-8.049 Y19.083 E0.0845
                                G1 X-7.228 Y18.592 E0.0393
                                G1 X-5.829 Y17.806 E0.0660
                                G1 X-2.005 Y15.805 E0.1774
                                G1 X-1.749 Y15.664 E0.0120
                                G1 X-0.741 Y15.031 E0.0489
                                G1 X-0.182 Y14.575 E0.0297
                                G1 X0.225 Y14.087 E0.0261
                                G1 X0.746 Y12.742 E0.0593
                                G1 X0.847 Y12.526 E0.0098
                                G1 X0.864 Y12.365 E0.0066
                                G1 X0.745 Y10.941 E0.0588
                                G1 X0.342 Y9.133 E0.0761
                                G1 X-0.212 Y7.194 E0.0829
                                G1 X-1.216 Y3.878 E0.1424
                                G1 X-1.686 Y2.198 E0.0717
                                G1 X-1.997 Y1.061 E0.0484
                                G1 X-2.338 Y-0.306 E0.0579
                                G1 X-2.657 Y-1.687 E0.0582
                                G1 X-3.138 Y-4.143 E0.1029
                                G1 X-3.300 Y-5.092 E0.0396
                                G1 X-3.519 Y-6.570 E0.0614
                                G1 X-3.767 Y-8.725 E0.0892
                                G1 X-3.921 Y-10.510 E0.0736
                                G1 X-4.038 Y-12.900 E0.0984
                                G1 X-4.060 Y-14.016 E0.0459
                                G1 X-4.047 Y-16.295 E0.0937
                                G1 X-3.986 Y-17.935 E0.0674
                                G1 X-3.894 Y-19.398 E0.0602
                                G1 X-3.771 Y-20.858 E0.0602
                                
                                

                                so it is a sequence of short extrusion moves the whole file. no long linear extrudes, just this.

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                                • undefined
                                  ofloveandhate
                                  last edited by 29 Jan 2018, 23:52

                                  here are my four attempts at 'seepferdchen'

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                                  • undefined
                                    ofloveandhate
                                    last edited by 29 Jan 2018, 23:54

                                    another thought: should i prefer absolute or relative extrusions? i have only been using relative through this whole process.

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                                    • undefined
                                      ofloveandhate
                                      last edited by 2 Feb 2018, 17:21

                                      i am starting to think there is a bug in the reprap firmware, in the part that processes relative extrusion distances. i printed the same model, same supports and all settings, last night. only change was that in simplify3d, i switched to absolute extrusion.

                                      ok, there was another difference that i should have not let happen, and that was that i printed this one without the https://www.thingiverse.com/thing:2567240 bottom corner plates.

                                      i am re-printing the same file now. if it fails again, then we know that the relative / absolute distances had nothing to do with my problem. if it succeeds, we have stronger evidence that it is a firmware bug.

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                                      • undefined
                                        ofloveandhate
                                        last edited by 5 Feb 2018, 14:34

                                        i am now convinced that there is a bug in the firmware dealing with relative extruder distances

                                        another success with absolute extruder distances, print time was 36h 21m

                                        video:
                                        https://youtu.be/7BCaq2k_oJk

                                        pic:

                                        a little problem at the top. caused due to top layers being set to 0 for that process in simplify3d. (6 processes used total, to reduce the amount of plastic used by varying the infill %)

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                                        • undefined
                                          dc42 administrators
                                          last edited by 6 Feb 2018, 00:02

                                          Most Duet users - including me - only ever use relative extrusion distances.

                                          Did you turn off "Allow zeroing of extrusion distance" in S3D? You should do that when using relative extrusion, although AFAIK it doesn't matter if you leave it enabled.

                                          Duet WiFi hardware designer and firmware engineer
                                          Please do not ask me for Duet support via PM or email, use the forum
                                          http://www.escher3d.com, https://miscsolutions.wordpress.com

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