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    Spurious Sensor Errors

    Scheduled Pinned Locked Moved
    Filament Monitor
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    • invertmastundefined
      invertmast @infiniteloop
      last edited by

      @infiniteloop said in Spurious Sensor Errors:

      @invertmast

      I'm running all of the sensor, stepper, fans, etc through a pair of cat6 ethernet cables between the Duet boards and the gantry. The MFM, Precision Peizo and hotend Fan run through one ethernet cable, while the parts fans, X endstop and stepper wiring runs through the other.

      You forgot to mention your hotend (heater and thermistor) - where did you put these, are they cat6, too?

      I just started a new print and within the first layer, i've had the printer pause 4 times due to "to little movement". Between the sensor error's and the to little movement, the sensor is basically worthless.

      The sensor is fine and works pretty well with the Duet 2, but with the original housing, they suffer from mechanical issues. I suggest you to try @lo-fi’s design instead. redesigned-the-mfm-housing

      Hotend is an E3D Volcano w/ a 1.2mm CHT nozzle. Its a direct drive setup with a BMG extruder.

      Heater and Thermistor are not cat 6, they are separated in a shielded cable.

      I tried printing Lo-fi's case a couple dozen times yesterday and never had any success, that may be bc i was trying to use silk pla. i'll retry later today with some abs. I do have a resin printer and am printing the original housing currently.. but even the MFM i have on my other printer with the printed supplied housing with it has the same problems.

      invertmastundefined infiniteloopundefined 2 Replies Last reply Reply Quote 0
      • invertmastundefined
        invertmast @invertmast
        last edited by

        One thing i have noticed with this MFM sensor is the mm per rev's are very spontaneous between prints and power cycles of the printer. It'll be in the mid 20's one time, then the next time i go to use the printer it will be in the mid 30's, i've even seen as high as 12,000 once before.

        9/17/2022, 9:04:08 AM 	M591 D0
        Duet3D rotating magnet filament monitor v4 on pin e0stop, disabled, sensitivity 26.17mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 130 agc 65, measured sensitivity 36.76mm/rev, min -4% max 140% over 9338.1mm
        
        9/17/2022, 9:08:19 AM 	M591 D0
        Duet3D rotating magnet filament monitor v4 on pin e0stop, disabled, sensitivity 26.17mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 133 agc 67, measured sensitivity 35.39mm/rev, min -4% max 138% over 11639.3mm
        
        9/17/2022, 9:08:26 AM 	M591 D0
        Duet3D rotating magnet filament monitor v4 on pin e0stop, disabled, sensitivity 26.17mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 132 agc 67, measured sensitivity 35.49mm/rev, min -4% max 138% over 11704.1mm
        
         9/17/2022, 9:11:49 AM 	M591 D0
        Duet3D rotating magnet filament monitor v4 on pin e0stop, disabled, sensitivity 26.17mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 132 agc 67, measured sensitivity 38.88mm/rev, min -4% max 151% over 13606.2mm
        
        
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        • infiniteloopundefined
          infiniteloop @invertmast
          last edited by

          @invertmast said in Spurious Sensor Errors:

          I tried printing Lo-fi's case a couple dozen times yesterday and never had any success

          You might have a hard time trying this with a 1.2 mm nozzle.

          @invertmast said in Spurious Sensor Errors:

          I do have a resin printer and am printing the original housing currently

          This should resolve the mechanical problems. On the electrical side, you can try to route the fan with lines separate from the cat6, that will improve the mfm's signal quality.

          @invertmast said in Spurious Sensor Errors:

          the mm per rev's are very spontaneous between prints

          In most cases, this indicates mechanical issues.

          invertmastundefined 1 Reply Last reply Reply Quote 0
          • invertmastundefined
            invertmast @infiniteloop
            last edited by

            @infiniteloop said in Spurious Sensor Errors:

            @invertmast said in Spurious Sensor Errors:

            I tried printing Lo-fi's case a couple dozen times yesterday and never had any success

            You might have a hard time trying this with a 1.2 mm nozzle.

            @invertmast said in Spurious Sensor Errors:

            I do have a resin printer and am printing the original housing currently

            This should resolve the mechanical problems. On the electrical side, you can try to route the fan with lines separate from the cat6, that will improve the mfm's signal quality.

            @invertmast said in Spurious Sensor Errors:

            the mm per rev's are very spontaneous between prints

            In most cases, this indicates mechanical issues.

            sorry, i tried printing the case on my other printer with a .4mm nozzle and .1mm layers. none came out well enough once it got to the standoffs that the circuit board mounts too.

            infiniteloopundefined 1 Reply Last reply Reply Quote 0
            • infiniteloopundefined
              infiniteloop @invertmast
              last edited by

              @invertmast said in Spurious Sensor Errors:

              none came out well enough once it got to the standoffs that the circuit board mounts to …

              … which affects the distance between magnet (on the hobbed assembly) and sensor. Printing the housing with a FDM printer, two other areas can be problematic: the filament path and the function of the idler (both free movement of the idler bearing and the corps of the idler).

              invertmastundefined 1 Reply Last reply Reply Quote 0
              • invertmastundefined
                invertmast @infiniteloop
                last edited by

                Finally got a decent housing printed out, assembled and a print going. Only to get a "sensor error" a little over an hour into this print.

                M591 D0
                Duet3D rotating magnet filament monitor v4 on pin e0stop, enabled, sensitivity 27.50mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 133 agc 51, measured sensitivity 27.25mm/rev, min 86% max 105% over 44253.9mm
                
                M122
                === Diagnostics ===
                RepRapFirmware for Duet 2 WiFi/Ethernet version 3.4.1 (2022-06-01 21:05:28) running on Duet WiFi 1.02 or later + DueX5
                Board ID: 08DGM-956GU-DJ3SJ-6J9DD-3SD6S-9UPZH
                Used output buffers: 3 of 26 (17 max)
                === RTOS ===
                Static ram: 23860
                Dynamic ram: 76472 of which 12 recycled
                Never used RAM 8544, free system stack 104 words
                Tasks: NETWORK(ready,41.9%,211) HEAT(notifyWait,0.2%,308) Move(notifyWait,5.5%,294) DUEX(notifyWait,0.0%,24) MAIN(running,52.3%,448) IDLE(ready,0.2%,30), total 100.0%
                Owned mutexes: WiFi(NETWORK)
                === Platform ===
                Last reset 01:48:25 ago, cause: software
                Last software reset at 2022-09-17 18:39, reason: User, GCodes spinning, available RAM 8064, slot 2
                Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
                Error status: 0x00
                Aux0 errors 0,0,0
                Step timer max interval 0
                MCU temperature: min 33.6, current 34.8, max 36.3
                Supply voltage: min 23.7, current 24.2, max 24.7, under voltage events: 0, over voltage events: 0, power good: yes
                Heap OK, handles allocated/used 99/1, heap memory allocated/used/recyclable 2048/12/0, gc cycles 0
                Events: 1 queued, 1 completed
                Driver 0: standstill, SG min 0
                Driver 1: standstill, SG min 0
                Driver 2: standstill, SG min 0
                Driver 3: standstill, SG min 0
                Driver 4: standstill, SG min n/a
                Driver 5: standstill, SG min 0
                Driver 6: standstill, SG min 0
                Driver 7: standstill, SG min 0
                Driver 8: standstill, SG min n/a
                Driver 9: standstill, SG min n/a
                Driver 10: 
                Driver 11: 
                Date/time: 2022-09-17 20:28:20
                Cache data hit count 4294967295
                Slowest loop: 81.53ms; fastest: 0.15ms
                I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
                === Storage ===
                Free file entries: 9
                SD card 0 detected, interface speed: 20.0MBytes/sec
                SD card longest read time 1.6ms, write time 1.9ms, max retries 0
                === Move ===
                DMs created 83, segments created 14, maxWait 586279ms, bed compensation in use: mesh, comp offset 0.000
                === MainDDARing ===
                Scheduled moves 34273, completed 34273, hiccups 0, stepErrors 0, LaErrors 0, Underruns [0, 0, 0], CDDA state -1
                === AuxDDARing ===
                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 -1 -1 -1 -1, ordering errs 0
                Heater 0 is on, I-accum = 0.0
                === GCodes ===
                Segments left: 0
                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
                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
                Daemon is idle in state(s) 0
                Autopause is idle in state(s) 0
                Code queue is empty
                === Filament sensors ===
                Extruder 0: pos 237.30, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
                === DueX ===
                Read count 1, 0.01 reads/min
                === Network ===
                Slowest loop: 169.04ms; fastest: 0.00ms
                Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
                HTTP sessions: 1 of 8
                - WiFi -
                Network state is active
                WiFi module is connected to access point 
                Failed messages: pending 0, notready 0, noresp 0
                WiFi firmware version 1.26
                WiFi MAC address 5c:cf:7f:76:63:7a
                WiFi Vcc 3.40, reset reason Turned on by main processor
                WiFi flash size 4194304, free heap 25192
                WiFi IP address 192.168.254.188
                WiFi signal strength -61dBm, mode 802.11n, reconnections 0, sleep mode modem
                Clock register 00002002
                Socket states: 0 0 0 0 0 0 0 0
                
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                • infiniteloopundefined
                  infiniteloop
                  last edited by

                  @invertmast

                  Only to get a "sensor error" a little over an hour into this print.

                  Usually, this indicates an electrical problem: overtalking or interference with other lines. to rule this out, keep the sensor's lines separate from all others and keep them (relatively) short.

                  Finally got a decent housing printed out …

                  Congrats! Is it a resin print?

                  invertmastundefined 1 Reply Last reply Reply Quote 0
                  • invertmastundefined
                    invertmast @infiniteloop
                    last edited by

                    @infiniteloop said in Spurious Sensor Errors:

                    @invertmast

                    Only to get a "sensor error" a little over an hour into this print.

                    Usually, this indicates an electrical problem: overtalking or interference with other lines. to rule this out, keep the sensor's lines separate from all others and keep them (relatively) short.

                    Finally got a decent housing printed out …

                    Congrats! Is it a resin print?

                    I have since re-routed all of the fan/stepper wires away from the sensor wiring. I have a print going now to see if that will work.

                    not a resin print, just a ffm print of lofi's case.

                    invertmastundefined 1 Reply Last reply Reply Quote 0
                    • invertmastundefined
                      invertmast @invertmast
                      last edited by

                      @invertmast

                      Sensor Error's still continue.

                      M122
                      === Diagnostics ===
                      RepRapFirmware for Duet 2 WiFi/Ethernet version 3.4.1 (2022-06-01 21:05:28) running on Duet WiFi 1.02 or later + DueX5
                      Board ID: 08DGM-956GU-DJ3SJ-6J9DD-3SD6S-9UPZH
                      Used output buffers: 3 of 26 (17 max)
                      === RTOS ===
                      Static ram: 23860
                      Dynamic ram: 76472 of which 12 recycled
                      Never used RAM 8088, free system stack 100 words
                      Tasks: NETWORK(ready,115.4%,229) HEAT(notifyWait,0.4%,308) Move(notifyWait,16.7%,295) DUEX(notifyWait,0.0%,24) MAIN(running,358.7%,440) IDLE(ready,0.5%,30), total 491.7%
                      Owned mutexes: WiFi(NETWORK)
                      === Platform ===
                      Last reset 02:52:12 ago, cause: power up
                      Last software reset at 2022-09-17 18:39, reason: User, GCodes spinning, available RAM 8064, slot 2
                      Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0041f000 BFAR 0xe000ed38 SP 0x00000000 Task MAIN Freestk 0 n/a
                      Error status: 0x08
                      Aux0 errors 0,1,0
                      Step timer max interval 0
                      MCU temperature: min 26.5, current 32.5, max 33.9
                      Supply voltage: min 23.7, current 24.2, max 24.7, under voltage events: 0, over voltage events: 0, power good: yes
                      Heap OK, handles allocated/used 99/1, heap memory allocated/used/recyclable 2048/12/0, gc cycles 0
                      Events: 2 queued, 2 completed
                      Driver 0: standstill, SG min 0
                      Driver 1: standstill, SG min 0
                      Driver 2: standstill, SG min 0
                      Driver 3: standstill, SG min 0
                      Driver 4: standstill, SG min n/a
                      Driver 5: standstill, SG min 0
                      Driver 6: standstill, SG min 0
                      Driver 7: standstill, SG min 0
                      Driver 8: standstill, SG min n/a
                      Driver 9: standstill, SG min n/a
                      Driver 10: 
                      Driver 11: 
                      Date/time: 2022-09-18 10:26:41
                      Cache data hit count 4294967295
                      Slowest loop: 144.69ms; fastest: 0.12ms
                      I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
                      === Storage ===
                      Free file entries: 9
                      SD card 0 detected, interface speed: 20.0MBytes/sec
                      SD card longest read time 1.7ms, write time 59.9ms, max retries 0
                      === Move ===
                      DMs created 83, segments created 33, maxWait 128221ms, bed compensation in use: mesh, comp offset 0.000
                      === MainDDARing ===
                      Scheduled moves 98460, completed 98460, hiccups 0, stepErrors 0, LaErrors 0, Underruns [1, 0, 0], CDDA state -1
                      === AuxDDARing ===
                      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 -1 -1 -1 -1, ordering errs 0
                      Heater 0 is on, I-accum = 0.0
                      === GCodes ===
                      Segments left: 0
                      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
                      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
                      Daemon is idle in state(s) 0
                      Autopause is idle in state(s) 0
                      Code queue is empty
                      === Filament sensors ===
                      Extruder 0: pos 268.95, errs: frame 0 parity 0 ovrun 0 pol 0 ovdue 0
                      === DueX ===
                      Read count 1, 0.01 reads/min
                      === Network ===
                      Slowest loop: 162.93ms; fastest: 0.00ms
                      Responder states: HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0), 0 sessions
                      HTTP sessions: 1 of 8
                      - WiFi -
                      Network state is active
                      WiFi module is connected to access point 
                      Failed messages: pending 0, notready 0, noresp 0
                      WiFi firmware version 1.26
                      WiFi MAC address 5c:cf:7f:76:63:7a
                      WiFi Vcc 3.40, reset reason Turned on by main processor
                      WiFi flash size 4194304, free heap 25352
                      WiFi IP address 192.168.254.188
                      WiFi signal strength -59dBm, mode 802.11n, reconnections 0, sleep mode modem
                      Clock register 00002002
                      Socket states: 4 0 0 0 0 0 0 0
                      
                      
                      m591 D0
                      Duet3D rotating magnet filament monitor v4 on pin e0stop, enabled, sensitivity 27.50mm/rev, allow 60% to 120%, check printing moves every 10.0mm, version 4, mag 132 agc 47, measured sensitivity 27.15mm/rev, min 69% max 106% over 72205.7mm
                      
                      infiniteloopundefined 1 Reply Last reply Reply Quote 0
                      • infiniteloopundefined
                        infiniteloop @invertmast
                        last edited by

                        @invertmast

                        Sensor Error's still continue.

                        The best advice I can give at this stage is to use another cable for the MFM lines - simply throw some wires in to test the efficiency of that measure.

                        min 69% max 106% over 72205.7mm
                        

                        The max value of 106% is fine, however, the min value reported looks a bit low to me: I'm not sure, but this might indicate a mechanical issue. Can you post a photo of how you've attached the MFM to your extruder?

                        invertmastundefined 1 Reply Last reply Reply Quote 0
                        • invertmastundefined
                          invertmast @infiniteloop
                          last edited by invertmast

                          Sensor is rigidly mounted via the short piece of bowden tube and via a bracket.

                          [image.jpg

                          For comparison, my other printer has the MFM remotely mounted from the extruder gantry and its wiring is completely seperate from anything else until it gets within the electronics enclosure. It has the same problems even with using shielded 3 conductor wiring.

                          edit-1 At this point, the sensor errors have gotten slightly better, but not much *Edit2,3,4 - they have not. I literally just had Six back to back within 5 minutes. They have gotten significantly worse in that the printer can't even get through a single layer now without a sensor error posting.

                          I’m at the point where i would rather just set up a macro where if it comes as as sensor error that it would just restart the print on its own.

                          infiniteloopundefined 1 Reply Last reply Reply Quote 0
                          • infiniteloopundefined
                            infiniteloop @invertmast
                            last edited by infiniteloop

                            @invertmast

                            I’m at the point where i would rather just set up a macro where if it comes as as sensor error that it would just restart the print on its own.

                            Try that.

                            @invertmast

                            not a resin print, just a ffm print of lofi's case.

                            Looking at the rather low "min" values reported, you might want to file a bit to smoothen operation of the idler and to widen the filament path (really just a little bit). It should be possible to limit deviation on the low side to far less than 10%. However, this does not affect the rate of "sensor error" messages.

                            EDIT: Thanks for the photo. I wanted to have a look at the filament path, but you've built it just fine 👍

                            invertmastundefined 2 Replies Last reply Reply Quote 0
                            • invertmastundefined
                              invertmast @infiniteloop
                              last edited by

                              @infiniteloop said in Spurious Sensor Errors:

                              @invertmast

                              I’m at the point where i would rather just set up a macro where if it comes as as sensor error that it would just restart the print on its own.

                              Try that.

                              @invertmast

                              not a resin print, just a ffm print of lofi's case.

                              Looking at the rather low "min" values reported, you might want to file a bit to smoothen operation of the idler and to widen the filament path (really just a little bit). It should be possible to limit deviation on the low side to far less than 10%. However, this does not affect the rate of "sensor error" messages.

                              EDIT: Thanks for the photo. I wanted to have a look at the filament path, but you've built it just fine 👍

                              i did clean up the idler path a bit by scraping some of the layer line texture away with an Xacto knife blade.. it felt pretty smooth, but i can recheck after this print completes. As for the filament path, i'll give it a cleaning with a small drill bit.

                              1 Reply Last reply Reply Quote 0
                              • invertmastundefined
                                invertmast @infiniteloop
                                last edited by

                                @infiniteloop said in Spurious Sensor Errors:

                                @invertmast

                                I’m at the point where i would rather just set up a macro where if it comes as as sensor error that it would just restart the print on its own.

                                Try that.

                                @invertmast

                                not a resin print, just a ffm print of lofi's case.

                                Looking at the rather low "min" values reported, you might want to file a bit to smoothen operation of the idler and to widen the filament path (really just a little bit). It should be possible to limit deviation on the low side to far less than 10%. However, this does not affect the rate of "sensor error" messages.

                                EDIT: Thanks for the photo. I wanted to have a look at the filament path, but you've built it just fine 👍

                                Thanks for the help the past few days. Still haven't figured out what is causing the sensor error's, even with running a separate 3 conductor shielded cable to the sensor outside of the drag chain from everything else. But, with the filament-error.g set to just ignore sensor error's, i've got mostly one entire print without an unnecessary pause.

                                infiniteloopundefined 1 Reply Last reply Reply Quote 0
                                • infiniteloopundefined
                                  infiniteloop @invertmast
                                  last edited by

                                  @invertmast

                                  Still haven't figured out what is causing the sensor error's, even with running a separate 3 conductor shielded cable to the sensor outside of the drag chain from everything else.

                                  Sorry to hear that. I have no further idea of potential reasons, although reading the forum quite intensely.

                                  With the filament-error.g set to just ignore sensor error's, i've got mostly one entire print without an unnecessary pause.

                                  Great! I’ll try that myself, especially as I just encountered some of those sensor errors during my latest print. Among them, there was a single nozzle jam reported, so I still think the MFM is an invaluable tool as it saved my 22-hour print.

                                  1 Reply Last reply Reply Quote 0
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