Magnetic Filament Sensor not working consistently.

clegg78

Hi there, I have 2 rotating filament sensors (the new 1.7a versions just received 2 weeks ago)

They are on the end of a Bowden tube so I expected some variance, but the readings are all over the place for a fast PLA print I am doing right now (Printing at 90mm/sec .4mm nozzle). I have an direct drive IDEX setup and don't want to put more mass on the extruders so the sensors are at the frame on the end of the bowden that feeds the extruders. Since I am printing with stiff PLA for this print I wasnt expecting such issues.

The sensors are wired to the CONN_LCD ports for Endstop 10 and 11.

Board info:

RepRapFirmware for Duet 2 WiFi/Ethernet version 2.05 running on Duet Ethernet 1.02 or later + DueX5
Board ID: 08DGM-917NK-F23T0-6J1F6-3SD6T-1GBWD
Used output buffers: 1 of 24 (21 max)

Filament sensor reading off M122:

=== Filament sensors ===
Extruder 0: pos 302.34, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
Extruder 1: pos 228.52, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0

Errors I am seeing in the eventlog.txt:

2020-01-05 14:17:05 Extruder 0 reports too little movement
2020-01-05 14:17:10 Printing paused at X-6.5 Y-95.0 Z11.1 U201.0
2020-01-05 14:18:15 Printing resumed
2020-01-05 14:18:29 Resume state saved
2020-01-05 14:18:29 Extruder 0 reports too little movement
2020-01-05 14:18:34 Printing paused at X-26.4 Y-95.0 Z11.1 U201.0
2020-01-05 14:19:02 Printing resumed
2020-01-05 14:39:41 Resume state saved
2020-01-05 14:39:41 Extruder 0 reports too little movement
2020-01-05 14:39:47 Printing paused at X97.9 Y-49.5 Z13.2 U201.0
2020-01-05 15:05:33 HTTP client 192.168.50.137 login succeeded
2020-01-05 15:07:19 Printing resumed
2020-01-05 15:14:43 Resume state saved
2020-01-05 15:14:43 Extruder 0 reports sensor not working
2020-01-05 15:14:48 Printing paused at X-89.0 Y-40.5 Z14.4 U201.0
2020-01-05 15:15:36 Printing resumed

The last error where it says the Extruder sensor not working was reported after I disabled the sensor with a M591 D0 S0 command!

The M591 D0 outputs I've been running between pauses are:

1/5/2020, 3:14:59 PM	M591 D0
Duet3D magnetic filament monitor on input 10, disabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 15.0mm, version 3, mag 129 agc 83, measured sensitivity 25.62mm/rev, min 96% max 104% over 1557.6mm
1/5/2020, 3:16:24 PM	M591 D0
Duet3D magnetic filament monitor on input 10, disabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 15.0mm, version 3, mag 129 agc 83, measured sensitivity 25.63mm/rev, min 98% max 104% over 181.1mm
1/5/2020, 3:15:52 PM	M591 D0
Duet3D magnetic filament monitor on input 10, disabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 15.0mm, version 3, mag 130 agc 83, measured sensitivity 25.82mm/rev, min 99% max 101% over 60.5mm
1/5/2020, 1:36:22 PM	M591 D0
Duet3D magnetic filament monitor on input 10, enabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 8.0mm, version 3, mag 131 agc 84, measured sensitivity 25.60mm/rev, min 97% max 104% over 81.1mm
1/5/2020, 2:17:36 PM	M591 D0
Duet3D magnetic filament monitor on input 10, enabled, sensitivity 25.00mm/rev, allow 20% to 150%, check every 8.0mm, version 3, mag 131 agc 85, measured sensitivity 25.89mm/rev, min -43% max 107% over 10639.6mm
1/5/2020, 1:33:31 PM	M591 D0
Duet3D magnetic filament monitor on input 10, enabled, sensitivity 25.00mm/rev, allow 40% to 150%, check every 8.0mm, version 3, mag 129 agc 84, measured sensitivity -27.51mm/rev, min 115% max 0% over 650.1mm

As you can see I kept moving the tolerances further apart, and even disabled the sensor and I am still getting these weird pauses/crashes.

Could this be an interference issues with the cable? CONN_LCD Endstop issue? The fact I am not seeing any error info out of the M122 for the magnetic sensor leaves me very confused.

Not sure what I should be doing here, now thats its pausing for even the "sensor not working" error... when the sensor is disabled. I am seeing consistent "green" on the sensor when printing is happening even in the instant that the pause happens.

clegg78

The full M122 is here:

=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.05 running on Duet Ethernet 1.02 or later + DueX5
Board ID: 08DGM-917NK-F23T0-6J1F6-3SD6T-1GBWD
Used output buffers: 3 of 24 (21 max)
=== RTOS ===
Static ram: 25712
Dynamic ram: 95048 of which 0 recycled
Exception stack ram used: 480
Never used ram: 9832
Tasks: NETWORK(ready,628) HEAT(blocked,1232) DUEX(suspended,160) MAIN(running,3728) IDLE(ready,160)
Owned mutexes:
=== Platform ===
Last reset 03:26:30 ago, cause: software
Last software reset at 2020-01-05 12:19, reason: User, spinning module GCodes, available RAM 9864 bytes (slot 1)
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task 0x4e49414d
Error status: 8
Free file entries: 8
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 0.0ms, max retries 0
MCU temperature: min 41.7, current 42.6, max 43.4
Supply voltage: min 23.9, current 23.9, max 24.1, under voltage events: 0, over voltage events: 0, power good: yes
Driver 0: ok, SG min/max 40/1023
Driver 1: standstill, SG min/max 406/1023
Driver 2: standstill, SG min/max 401/1023
Driver 3: standstill, SG min/max 0/238
Driver 4: standstill, SG min/max not available
Driver 5: standstill, SG min/max not available
Driver 6: ok, SG min/max 15/1023
Driver 7: ok, SG min/max 29/1023
Driver 8: standstill, SG min/max not available
Driver 9: standstill, SG min/max not available
Date/time: 2020-01-05 15:46:07
Cache data hit count 4294967295
Slowest loop: 6.28ms; fastest: 0.09ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Move ===
Hiccups: 0, FreeDm: 155, MinFreeDm: 97, MaxWait: 0ms
Bed compensation in use: mesh, comp offset 0.000
=== DDARing ===
Scheduled moves: 86200, completed moves: 86160, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.1
Heater 1 is on, I-accum = 0.5
=== GCodes ===
Segments left: 1
Stack records: 3 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 doing "G1 X85.111 Y104.983 E1.2412" 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 ===
Slowest loop: 15.26ms; fastest: 0.05ms
Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8
Interface state 5, link 100Mbps full duplex
=== Filament sensors ===
Extruder 0: pos 75.23, errs: frame 1 parity 0 ovrun 0 pol 0 ovdue 0
Extruder 1: pos 227.81, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0