We have arrived at the moment of truth.

Friday I assembled the molds with, as you can see, the white pieces in there to make bolt holes and a piece of rebar in the center. Saturday I mixed up another 3 bags of concrete mix and did the pour. Then finally on Tuesday, I demolded the slabs and attached them to the printer. Before I go over the results, I'll share some more of my experiences and remarks.

Removing the wood mold pieces went very very easy just like last time. The white inserts for molding the bolt holes were not. From the 40 spread over the two slabs, just four came out with gentle percussive action. I did have a 1,5° taper angle on the pieces, but I ended up needing to use a drill to get rid of most of the plastic. The last cleanup was done using a hot air station at 200°C. The holes are not perfectly smooth around the edges, but no major issues.

Last time I noticed that the sides touching the mold wood were quite dusty and remained quite dusty no matter what I did. I did a quick google and assumed bad mixing was to blame for that. On the two new slabs I notice the same however, yet that could be due to me using the same mixing ratios. But actually I now believe it is due to the wood absorbing moisture from the concrete while it is still wet, thus effectively causing localized bad mixing. I figured this as I poured the excess concrete in a plastic bucket and after drying is was completely dust free. The wood absorbing moisture also explains why the top surface did not show the same issue.

I decided to add a piece of rebar in the center to give some added strength as the piece is quite thin compared to its length and did not want it cracking in half while working with it. The picture below shows how I suspended the rebar with some metal wire between the printed pieces. After demolding I noticed something interesting. In both slabs I can feel something moving quite distinctly when I jiggle a little with the slab upright. It really feels like the rebars are loosey goosey in there Don't ask my why, and I guess at this point it doesn't really matter that much either.

While playing with the first slab, I became clear that it did not sit perfectly straight against the tower. I got a piece of ~3mm rubber matting from a local home improvement store that sold it by the meter. I cut six pieces sized and holed correctly for the slab so I could double up on the thickness if needed. In the end I did end up just using one piece per tower, but oh well.

Now it is finally time for the moment of truth, attaching the slabs to the towers. At a little of 30kg a piece it was not trivial but I managed to get them one there. Some bolt holes are left open as one or two holes are badly located and do not line up well enough, or the t-nut fell down while playing with the bolt and I did not feel like removing the slab to put a t-nut back . Once I attached the first slab and even the second I did some test moves and was not really impressed with what I heard. But the third was the charm I guess, definitely an improvement. I can no longer feel any vibrations with my hands on the towers.

I must nuance the results a bit sadly. While the difference is certainly there and is quite noticeable, it's not perfect and not really acceptable even. I went from being able to hear the printer form all areas of the house to only audible in the next room. To combat the last noise I have some proper nema 23 dampers on order and I am most likely going to construct some sort of enclosure for the entire printer, that I line with sound dampening material.

Congrats to the people that made it this far down the wall of text, enjoy the pictures and drop an upvote if you think these longer post as worth the time Many thanks to all that pitched in with ideas and suggestions.

Just for the curious among us, this ended up costing my about €165, of which almost half went to the M8 t-nuts and the blue pigment.

@sneakyferret if it is of any use, I van provide a data point. My wiring to the smarteffector is a good 2m long and has been working for years without a hint of problems.

-Nxt

@Kolbi From own experience with the rubber isolation rings I can attest that they are more than rigid enough so that motor orientation is of no concern whatsoever. At least for sizes that I worked with (nema 17 and recently 23). What might be more of an issue is load tangential to the motor axis. About a year ago I actually removed these style isolation rings from my printer as my (high) belt tensions would cause the assembly to flex out of alignment. In recent months I circumvented this issue by adding an extra bearing to the stepper shaft, opposite of the pulley.

There style dampers are excellent at what they do however. Due to the fact that is no other path for vibrations to travel from the motor to a motor mount (except for through the shaft, but you can't everything rubber right ). The cock pads are in my experience worthless for that same reason. No matter how ideal there vibration absorption characteristics are, there will always be a direct path to the motor mount via the bolts.

The following threads that I started might all be of interest for you. Keep in mind most of these are quite long (and not always a pleasant read )and still ongoing.
https://forum.duet3d.com/topic/14674/external-bearings-for-stepper-shafts
https://forum.duet3d.com/topic/17513/to-rigidify-or-not-to-rigidify-vibration-issues
https://forum.duet3d.com/topic/17725/building-a-sound-dampening-enclosure

After further debating it with my machining guy, we ended up turning down the heatsink top shaft to 12mm diameter and not thread it at all. To be able to clamp it, a simple 10mm high spacer was machined to sit between the redish washer at the top of the pcb and the bottom of the screw in bowden connector. This way the bowden fitting effectively does the clamping.

@jrcl Since the new heater tuning model got implemented, tuning on large thermal mass beds has been known to take a while. As it happens I tuned my 2kW bed just last weekend and that took several hours.
So what you encountered might in fact be just normal behaviour.

@topenga I belive this should put you on the right track https://github.com/Duet3D/Duet-2-Hardware/tree/master/Duet2/Duet2v1.04

@phaedrux said in Duet2 connection interrupted: Let's get to the bottom of this:

@nxt-1 Would you be able to collect a wireshark trace?

1.pcapng.c
2.pcapng.c
3FullDataset.pcapng.c
Here you go, the .c extension needs to be removed abviously, the forum doesn't allow from .pcapng files The first two datasets were started when I notices warning popping up in dwc, so they are probabily missing the first pieces of vital information. The 3rd set contains everything from start to finish.

Note: all these traces were without the new v1.26 debug firmware as sugested by @chrishamm. I will install that now and report back.

@infidelprops Pluggin your exact question in the ol' google produced these:

• Duet 2
• Duet 3 Mini
• Duet 3 6HC

After 4,5 days of heating plastic, tearing it of and burning my hands, the mold is finally entirely removed. Some results/remarks can be made already, so it is time for an update again.

First, the center of the cast is not looking great, even though you one hopes for the best, this does not come as a surprise. While making the cast, the machine was placed on top of the empty mold and then the mold was filled from the sides. Therefore, the EG mix will not reach the upper-inner most edge of the mold without a large vibration insert or heavy duty compacting. Physics I guess This part of the mold is never visible to could be worse I guess.

The DIY threaded inserts I made work a treat and the rubber machine leveling feet screw in nicely.

The machine is now standing up again and looking solid. Before I stud it upright, I grabbed some scales to get a measurement on my craziness. On scale sat at the very top end a measured 13kg, the other one was placed at the other side about 20cm from the bottom plane of the printer, showing 95kg. Quick mafs leads to 98kg at this moment (this will still increase later on, keep reading ).

Up next is mainly cleanup and finishing work. At the edges of the mold and where different mold pieces interfaced, there were some epoxy ridges that I already removed with a rotary hammer (that was overkill for the job tbh). I still plan to further smooth rough edges with a flap wheel on an angle grinder, as sand paper on this material seems to be not exactly my definition of 'fun'. I am still debating whether I am going to buy and apply some kind of clear epoxy top coat to seal the whole deal (mainly the sides) and give it some more of that glossy finish.

I mentioned that the 98kg is still going to increase and that is because what got this party started in the 1st place is the cavities in the three main extrusions. At the moment, these are still hollow but will get filled with the same white sand that I used in the EG mix. I expect this will add an extra 5-10kg of fun to the machine.

Last, I think I might need to get rid of smurf evidences on my floor. If that's even possible, because it seems pretty well pigmented on there.

@Danal said in Delta proper endstop upgrade - advice welcome:

LOVE the custom pins, probably took you forever to get JUST enough iron oxide to act as a lubricant/traction interface without overwhelming the arc reactor. Microgram scale for weight/adjustment, no doubt.

You are correct getting the oxide layer just the right thickness and purity took several attempts and is not recommend for the faint of hearth. I am not sure when I started the process, but it might be over 20 years ago

@Nate-Nygren Jetson Nano 4GB here

@sneakyferret if it is of any use, I van provide a data point. My wiring to the smarteffector is a good 2m long and has been working for years without a hint of problems.

-Nxt

@Torin So, it's been a while. I finaly broke down and installed a Go environment so I can play around with your project.

What I belive is going on is that there is rrf3 and 2, which your latested beta does differentiate between, though not entirely correct. Within rrf3 a subdivision must be made between the SBC version and the standalone version. The standalone version (rrf3) will get detected as is and work as intended (I assume I cannot test this). Rrf2 will also work I believe (again, I cannot test this). However, SBC mode (rrf3) will not work since it uses the /machine/status syntax which will lead it down the rrf2 branch of your code. That wont work as rr_status is deprecated and returns resulting in a empty response. Which is obviously not json parsable, hence the continuous json errors I reported earlier. @chrishamm please correct me if I am wrong at any point here.

What I belive needs to change to make all of this work:

• Expand the api version check in main to handle rrf3 sbc as a separate case (or pass the version/type as a config parameter again)
• Make a 3rd handler for rrf3 sbc that uses /machine/status to get the full object model and takes the data it needs from it
  -> I've changed the v2handler to package for now as an example on how this could work, check the files attached below

Some other changes I think would be useful if added:

• Make the connection protocol part of the host parameter. I.e. add the http part in there as well. For example my machine normally does not listen to http requests so making this user changeable would save some hassle on my side
• Add the same delay to the loop in case of errors, so the loop does not run at mach3

======================
Example implementation for rrf3 sbc handler (currently sits in place of the v2 handler)
v2_handler.gcode
types.gcode

@torin said in notifications upon start/pause/finish of print:

@nxt-1 Interesting, can you provide me full curl of:

curl -v 'http://localhost:8080/rr_status?type=3'
curl -v http://localhost:8080/rr_fileinfo

(those two below probably will not work)
curl -v 'http://localhost:8080/rr_model?key=job'
curl -v 'http://localhost:8080/rr_model?key=state'

curl -v 'http://localhost:8080/rr_status?type=3' -> 404
curl -v http://localhost:8080/rr_fileinfo -> 404
curl -v 'http://localhost:8080/rr_model?key=job' -> 404
curl -v 'http://localhost:8080/rr_model?key=state' -> 404

Which makes sense, since Chrishamm mentioned the rr_ system wil be introduced in v3.5

@torin /machine/status does give me a wall of json output .

curl -v http://localhost:8080/machine/status
*   Trying 127.0.0.1...
* TCP_NODELAY set
* Connected to localhost (127.0.0.1) port 8080 (#0)
> GET /machine/status HTTP/1.1
> Host: localhost:8080
> User-Agent: curl/7.58.0
> Accept: */*
> 
< HTTP/1.1 200 OK
< Content-Length: 14094
< Content-Type: application/json
< Date: Wed, 20 Jul 2022 13:45:18 GMT
< Server: Kestrel
< 
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Connection #0 to host localhost left intact
50,"ioBits":0,"laserPwm":null,"spindleSpeeds":[],"toolNumber":-1}],"status":"idle","thisInput":null,"time":"2022-07-20T15:44:46","upTime":4052689},"tools":[{"active":[0],"axes":[[0],[1]],"extruders":[0],"fans":[0],"feedForward":[0],"filamentExtruder":0,"heaters":[1],"isRetracted":false,"mix":[1],"name":"Hotend","number":0,"offsets":[0,0,0],"offsetsProbed":0,"retraction":{"extraRestart":0,"length":0.9,"speed":45,"unretractSpeed":45,"zHop":0.1},"spindle":-1,"spindleRpm":0,"standby":[0],"state":"active"}],"userSessions":[{"accessLevel":"readWrite","id":33,"origin":"94.105.126.101","originId":-1,"sessionType":"http"}],"volumes":[{"capacity":236242378752,"freeSpace":220662013952,"mounted":true,"name":null,"openFiles":null,"partitionSize":236242378752,"path":"/","speed":null}]}

However launching the updated executable I get continous json errors:
(I am running rrf 3.4.1 fyi)

./reprap_notify_linux_arm64 
2022/07/20 15:48:57 Detecting API version... 
2022/07/20 15:48:57 Detected firmware revision 2
2022/07/20 15:48:57 Error parsing JSON: unexpected end of JSON input
2022/07/20 15:48:57 Error parsing JSON: unexpected end of JSON input

@torin said in notifications upon start/pause/finish of print:

@nxt-1 Right, so the second paste is wrong and missing URI

I did in fact ment to post it without URI, just to show that can I fact make a connection.

Here's the two requests, as requested

curl -v http://localhost:8080/machine/system
*   Trying 127.0.0.1...
* TCP_NODELAY set
* Connected to localhost (127.0.0.1) port 8080 (#0)
> GET /machine/system HTTP/1.1
> Host: localhost:8080
> User-Agent: curl/7.58.0
> Accept: */*
> 
< HTTP/1.1 404 Not Found
< Content-Length: 0
< Date: Tue, 19 Jul 2022 15:39:09 GMT
< Server: Kestrel
< 
* Connection #0 to host localhost left intact

curl -v "http://localhost:8080/rr_model?key=boards"
*   Trying 127.0.0.1...
* TCP_NODELAY set
* Connected to localhost (127.0.0.1) port 8080 (#0)
> GET /rr_model?key=boards HTTP/1.1
> Host: localhost:8080
> User-Agent: curl/7.58.0
> Accept: */*
> 
< HTTP/1.1 404 Not Found
< Content-Length: 0
< Date: Tue, 19 Jul 2022 15:39:18 GMT
< Server: Kestrel
< 
* Connection #0 to host localhost left intact

@torin They result in a 404 for both, though I would not be able to guess why since the base address does seem to be reachable, though understandably complaining about the lack of JS.

curl -v http://localhost:8080/rr_model?key=boards
*   Trying 127.0.0.1...
* TCP_NODELAY set
* Connected to localhost (127.0.0.1) port 8080 (#0)
> GET /rr_model?key=boards HTTP/1.1
> Host: localhost:8080
> User-Agent: curl/7.58.0
> Accept: */*
> 
< HTTP/1.1 404 Not Found
< Content-Length: 0
< Date: Tue, 19 Jul 2022 14:44:56 GMT
< Server: Kestrel
< 
* Connection #0 to host localhost left intact

curl -v http://localhost:8080
* Rebuilt URL to: http://localhost:8080/
*   Trying 127.0.0.1...
* TCP_NODELAY set
* Connected to localhost (127.0.0.1) port 8080 (#0)
> GET / HTTP/1.1
> Host: localhost:8080
> User-Agent: curl/7.58.0
> Accept: */*
> 
< HTTP/1.1 200 OK
< Content-Length: 1441
< Content-Type: text/html
< Date: Tue, 19 Jul 2022 14:47:27 GMT
< Server: Kestrel
< Accept-Ranges: bytes
< ETag: "1d8772d0a7368a1"
< Last-Modified: Fri, 03 Jun 2022 09:33:54 GMT
< 
<!DOCTYPE html><html lang="en"><head><meta charset="utf-8"><meta http-equiv="X-UA-Compatible" content="IE=edge"><meta name="viewport" content="width=device-width,initial-scale=1,user-scalable=0"><!--[if IE]><link rel="icon" href="/favicon.ico"><![endif]--><title>Duet Web Control</title><link href="/css/app.62f87138.css" rel="preload" as="style"><link href="/js/app.d9dc885b.js" rel="preload" as="script"><link href="/css/app.62f87138.css" rel="stylesheet"><link rel="icon" type="image/png" sizes="32x32" href="/img/icons/favicon-32x32.png"><link rel="icon" type="image/png" sizes="16x16" href="/img/icons/favicon-16x16.png"><link rel="manifest" href="/manifest.json"><meta name="theme-color" content="#2196f3"><meta name="apple-mobile-web-app-capable" content="yes"><meta name="apple-mobile-web-app-status-bar-style" content="black"><meta name="apple-mobile-web-app-title" content="Duet Web Control"><link rel="apple-touch-icon" href="/img/icons/apple-touch-icon-152x152.png"><link rel="mask-icon" href="/img/icons/safari-* Connection #0 to host localhost left intact
pinned-tab.svg" color="#2196f3"><meta name="msapplication-TileImage" content="/img/icons/msapplication-icon-144x144.png"><meta name="msapplication-TileColor" content="#000000"></head><body><noscript><strong>We're sorry but Duet Web Control does not work properly without JavaScript enabled. Please enable it to continue.</strong></noscript><div id="app"></div><script src="/js/app.d9dc885b.js"></script```

@torin I tried the new version but could not get past identifying v2 of v3 firmware.

Printer is a Duet3 6HC in SBC mode, attached to a Jetson Nano (arm64). That name Nano also runs your project.

Top of rrnotity.yaml looks like this (dwc is running on port 8080)

connection:
  host: localhost:8080
  polling_time: 5
  error_count: 50
  api_version: v3

Running the rr_notify results is this output:

2022/07/19 00:40:18 Detecting API version... 
2022/07/19 00:40:18 Couldn't identify v2 or v3 firmware
panic: Couldn't identify v2 or v3 firmware

goroutine 1 [running]:
log.Panicf({0x463b71?, 0x454fd0?}, {0x0?, 0x1?, 0x400022a030?})
	/usr/local/go/src/log/log.go:392 +0x6c
main.main()
	/builds/Toriniasty/reprap_notify/cmd/rr_notify/main.go:71 +0x46c

I am not sure how to proceed from here or how to debug. ¯_(ツ)_/¯

@threepwood If your rail is out of spec and a genuine part you can always contact the supplier. That being said, if it were my rail I would not mind taking it appart and reassembling it ¯_(ツ)_/¯.

@threepwood I disassembled a number of linear rails including MGN12's. I don't see a specific reason to not do it appart from that it can be tedious. Once the rail is out of the cariage, there isn't much keeping the balls in check (the little metal bar inside is far from 100%) and boy do they like to go everywhere if they get a chance to bounce. My advice would be to disassemble them inside or over a container so you don't lose any balls. Also getting the cariage back on the rail can a hassle for the same reason.

I have not worked with the MGN9 size personaly but I imagine it is idential, perhaps with even smaller balls.