Stall detection setup - nothing but false stalls
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Can you provide the results of M122 please?
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Hi Phaedrux,
I've parked this momentarily, and started another print, so I don't know how useful the M122 output will be. Here it in in any case:
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M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.05 running on Duet WiFi 1.02 or later + DueX5
Board ID: 08DJM-9178L-L2MSD-6JKD6-3S86K-19D2N
Used output buffers: 3 of 24 (20 max)
=== RTOS ===
Static ram: 25712
Dynamic ram: 94352 of which 28 recycled
Exception stack ram used: 448
Never used ram: 10532
Tasks: NETWORK(ready,628) HEAT(blocked,1232) DUEX(suspended,160) MAIN(running,3752) IDLE(ready,160)
Owned mutexes:
=== Platform ===
Last reset 00:34:17 ago, cause: software
Last software reset at 2020-11-13 10:39, reason: User, spinning module GCodes, available RAM 10540 bytes (slot 2)
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0441f000 BFAR 0xe000ed38 SP 0xffffffff Task 0x4e49414d
Error status: 0
Free file entries: 9
SD card 0 detected, interface speed: 20.0MBytes/sec
SD card longest block write time: 3.4ms, max retries 0
MCU temperature: min 35.1, current 36.1, max 36.7
Supply voltage: min 11.4, current 11.5, max 12.3, under voltage events: 0, over voltage events: 0, power good: yes
Driver 0: ok, SG min/max 0/491
Driver 1: ok, SG min/max 0/420
Driver 2: standstill, SG min/max not available
Driver 3: standstill, SG min/max not available
Driver 4: ok, SG min/max 0/72
Driver 5: ok, SG min/max 0/568
Driver 6: ok, SG min/max 0/488
Driver 7: ok, SG min/max 0/1023
Driver 8: ok, SG min/max 0/1023
Driver 9: standstill, SG min/max not available
Date/time: 2020-11-13 11:14:11
Cache data hit count 4294967295
Slowest loop: 90.29ms; fastest: 0.07ms
I2C nak errors 0, send timeouts 0, receive timeouts 0, finishTimeouts 0, resets 0
=== Move ===
Hiccups: 0, FreeDm: 156, MinFreeDm: 116, MaxWait: 579021ms
Bed compensation in use: mesh, comp offset 0.000
=== DDARing ===
Scheduled moves: 4019, completed moves: 3996, StepErrors: 0, LaErrors: 0, Underruns: 0, 0
=== Heat ===
Bed heaters = 0 -1 -1 -1, chamberHeaters = -1 -1
Heater 0 is on, I-accum = 0.4
Heater 1 is on, I-accum = 0.3
=== GCodes ===
Segments left: 1
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 doing "G1 X238.265 Y386.36 E0.02739" 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: 18.11ms; fastest: 0.01ms
Responder states: HTTP(2) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8- WiFi -
Network state is running
WiFi module is connected to access point
Failed messages: pending 0, notready 0, noresp 0
WiFi firmware version 1.21
WiFi MAC address cc:50:e3:e3:b1:11
WiFi Vcc 3.28, reset reason Turned on by main processor
WiFi flash size 4194304, free heap 16864
WiFi IP address 192.168.0.112
WiFi signal strength -45dBm, reconnections 0, sleep mode modem
Socket states: 0 4 0 0 0 0 0 0
=== Filament sensors ===
Extruder 0: pos 1.02, errs: frame 0 parity 0 ovrun 0 pol 2 ovdue 0
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@Gerrard said in Stall detection setup - nothing but false stalls:
Hi Frederick - I'm looking to use stall detection to detect skipped steps, not for sensorless homing. Have I missed something? Are they mutually dependant? I can't have limit switches and stall detection?
Sorry - my bad - I thought you were talking about sensorless homing.
So that lead me to another question: If you get stall detection working what benefits do you see that it will provide?
Once steps have been skipped I cannot think of anyway to get everything back in sync - is there some way?
Thanks.
Frederick
Printers: A FT-5 with the 713 upgrade bits, a custom MarkForged style, a small Utilmaker style, a small CoreXY from kit and a E3D MS/TC setup. Various hotends. Using Duets (2 and 3) running 3.4.6
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@fcwilt There's one reason why stall detection will help - see pic attached.
If skipped steps are effectively detected I can a) pause the print to avoid wasting filament and/or b) re-home (with physical switches) the hot end carriage and continue printing.
This mess equates to most of a roll of filament, and about 24hrs print time wasted. Both skipped, and continued printing. If they stopped when the skip was detected, then they would have been salvageable.
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@Gerrard said in Stall detection setup - nothing but false stalls:
I don't know how useful the M122 output will be. Here it in in any case:
M122
=== Diagnostics ===
RepRapFirmware for Duet 2 WiFi/Ethernet version 2.05 running on Duet WiFi 1.02 or later + DueX5That's fine. I just wanted to know what Duet and firmware you're using.
Can you also post your full config.g and whatever macros you're using to setup the stall detection, if any.
Is there a pause.g in your /sys folder?
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@fcwilt said in Stall detection setup - nothing but false stalls:
Once steps have been skipped I cannot think of anyway to get everything back in sync - is there some way?
Well if the stall is detected by the driver it can either pause the print and wait for you to decide what to do or rehome XY and continue printing under the assumption that it will return to the same position as it was when originally homed before the stall.
@Gerrard said in Stall detection setup - nothing but false stalls:
If skipped steps are effectively detected I can a) pause the print to avoid wasting filament and/or b) re-home (with physical switches) the hot end carriage and continue printing.
Ideally, yes, but but detecting the stall isn't as good as preventing the stall in the first place. If steps are being lost on a regular basis there's something wrong. Either motor current not adequate, mechanical binding, or prints curling up due to lack of cooling. Solving those root causes will be far more effective than detecting the stall afterwards, because if you catch it and resume, another stall could be just around the corner.
Regardless, it can be a useful feature and it should be working. Once you share your config files we will have a better idea of what's going on.
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@Gerrard said in Stall detection setup - nothing but false stalls:
@fcwilt There's one reason why stall detection will help - see pic attached.
If skipped steps are effectively detected I can a) pause the print to avoid wasting filament and/or b) re-home (with physical switches) the hot end carriage and continue printing.This mess equates to most of a roll of filament, and about 24hrs print time wasted. Both skipped, and continued printing. If they stopped when the skip was detected, then they would have been salvageable.
Interesting.
I've never had the kind of a mess while printing BUT being a cautious person I stay near the printer when powered on.
Normally things only go wrong when you are not around - seems to be a law of the universe.
Thanks and good luck.
Frederick
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@fcwilt Those prints take 30-40hrs or more, so i'm not hanging around that long. The part you see in the background is almost 500mm long for reference.
@Phaedrux
config.g is below.
; Configuration file for Duet WiFi (firmware version 2.03)
; executed by the firmware on start-up
;
; generated by RepRapFirmware Configuration Tool v2.1.8 on Mon Mar 30 2020 11:14:18 GMT+1000 (Australian Eastern Standard Time); General preferences
G90 ; send absolute coordinates...
M83 ; ...but relative extruder moves
M550 P"Point Zero CoreXY" ; set printer nameM667 S1 ; select CoreXY mode
; Network
M552 S1 ; enable network
M586 P0 S1 ; enable HTTP
M586 P1 S0 ; disable FTP
M586 P2 S0 ; disable Telnet; Drives
M569 P0 S1 ; physical drive 0 goes backwards
M569 P1 S1 ; physical drive 1 goes forwards
M569 P5 S0 ; physical drive 5 goes backwards
M569 P6 S0
M569 P7 S0
M569 P8 S0
M569 P4 S0 ; physical drive 3 goes backwards
M584 X1 Y0 Z5:6:7:8 E4 ; set drive mapping
M671 X200,400,200,400 Y-60,-60,875,875 ; Set location of z leadscrews for independant bed levelling.
M350 X16 Y16 Z16 E16 I1 ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z1600.00 E412.0 ; set steps per mm
M566 X600.00 Y600.00 Z20.00 E1200.00 ; set maximum instantaneous speed changes (mm/min) *** PREVIOUS VALUES X&Y:600 Z12 E900
M203 X8000.00 Y8000.00 Z400.00 E1500 ; set maximum speeds (mm/min)
M201 X800.00 Y800.00 Z100.00 E600.00 ; set accelerations (mm/s^2) *** PREVIOUS VALUES X400 Y400.00 Z10.00 E150.00
M204 P1200 T4000 ; print and travel acceleration
M906 X1200 Y1200 Z800 E1200 I30 ; set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout
M593 F80 ; Set Dynamic Acceleration Adjustment
M572 D0 S0.05 ; Set extruder pressure advance
;M915 P0:1 S3 F1 H200 R1 ; Set up stall detection; Axis Limits
M208 X0 Y0 Z0 S1 ; set axis minima
M208 X860 Y800 Z750 S0 ; set axis maxima; Endstops
M574 X1 Y1 Z1 S0 ; set active high endstops
M591 D0 P5 C3 R5:120 E20.0 S1 ; Configure Laser filament sensor for extruder drive 0.; Z-Probe
M307 H3 A-1 C-1 D-1 ; disable heater on PWM channel for BLTouch
M558 P9 H5 F120 T6000 ; set Z probe type to bltouch and the dive height + speeds
G31 P500 X-21.6 Y9.4 Z3.2 ; set Z probe trigger value, offset and trigger height - **PREVIOUS Z VALUE = Z1.35
M557 X40:800 Y40:760 S78 ; define mesh grid - AS DESIGNED
;M557 X270:530 Y270:530 S52 ; define mesh grid - FOR TESTING ONLY
M376 H5 ; Set bed compensation taper (layers to fade out bed compensation)
G29 S1; Heaters
M307 H0 B0 S1.00 ; disable bang-bang mode for the bed heater and set PWM limit
M305 P0 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 0
M143 H0 S120 ; set temperature limit for heater 0 to 120C
M305 P1 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 1
M143 H1 S280 ; set temperature limit for heater 1 to 280C
M305 P2 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 1
M143 H2 S280 ; set temperature limit for heater 1 to 280C; Fans
M106 P0 S0 I0 F25000 H1 T45 ; set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned on
M106 P1 S1 I0 F500 H-1 ; set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned off; Tools
M563 P0 D0 H1 F0 ; define tool 0
G10 P0 X0 Y0 Z0 ; set tool 0 axis offsets
M563 P1 D0 H2 F0 ; define tool 1
G10 P1 X0 Y20 Z0 ; set tool 1 axis offsets
G10 P1 R0 S0
G10 P0 R0 S0 ; set initial tool 0 active and standby temperatures to 0C; Custom settings are not defined
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@Phaedrux I have just aborted the last print installed 2x new Nema17 motors on A/B axis (the courier dropped them off since I posted this problem earlier this morning), they're 50% larger than the ones I had before, and using the hand-ometer they feel MUCH more firm in terms of holding torque. The whole system is quite large, so there's no surprise that the smaller motors were out classed.
The stall detection was a hail-mary, but I think these larger motors will make the problem a non-issue - I'll know in about 30hrs...
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M305 P0 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 0
M305 P1 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 1
M305 P2 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 1B4138 is the default and wrong for your thermistors. look up the correct value in your thermistor documentation
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@Gerrard said in Stall detection setup - nothing but false stalls:
; Axis Limits
M208 X0 Y0 Z0 S1 ; set axis minima
M208 X860 Y800 Z750 S0 ; set axis maximaYes that's a very large corexy machine. That will make tuning stall detection even harder as at that size you've got a lot of compliance in the belts and long extrusions. Detecting a stall during a print would be difficult.
Hopefully your new motors are better suited and it becomes a non issue.
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Well, I let the print run over night and awoke to find another spaghetti mess.
I've re-tried tuning the stall detection with the bigger motors and it seems to be working better - far fewer false stalls - so I'll keep tweaking this until I'm happy.However, after looking long and hard at the print that failed, and the console logs, it looks as though it stalled because the z height drivers failed (overheat), and the print continued causing an inevitable crash scenario... I'll explore this a little more and post a separate thread if I can't find a solution.
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Motor currents should be around 80% off rated max. Did you change the config for the new motors?
Is the nozzle getting caught on curling print?
