Duet3D 1HCL - Closed Loop Controller Beta test

MaxGyver

Short update:

I am on my third print with the closed loop drivers and so far they are working quite well. The axes are sticking to their position very well. I really have to apply a lot of force to push them off course, and they will snap right back.

I am printing with up to 300mm/s and was able to increase my acceleration and jerk significantly. On the downside I had to limit my max. speeds to 20000mm/min or 300mm/s.

@lirwin17 I have two motors on my Y axis. They are both wired to one 1HCL board, but only one has an encoder. It calibrates fine, and I did not spot a significant problem during printing. Only the recorded graphs were of no use on this axis (at least for me). Maybe something to keep in mind for future development.(especially for autotuning. )

Furthermore, I have the impression that the drivers run in full step without any microstepping as soon as I switch to closed loop. It sounds very much like my very first printer. The prints also show a strong stepping pattern.

Cheers Max

supertb1

@lirwin17
After change to P50.0
Error: Response timeout: CAN addr 51, req type 6045, RID=27
Pulse-type filament monitor on pin io5.in, enabled, sensitivity 7.000mm/pulse, allowed movement 55% to 150%, check every 22.0mm, no data received
Error: bad model parameters
9/21/2021, 7:14:52 AM Error: Response timeout: CAN addr 51, req type 6043, RID=25
9/21/2021, 7:14:51 AM Error: Response timeout: CAN addr 51, req type 6042, RID=23
9/21/2021, 7:14:50 AM Error: Response timeout: CAN addr 51, req type 6042, RID=21
9/21/2021, 7:14:49 AM Error: Response timeout: CAN addr 51, req type 6042, RID=19
9/21/2021, 7:14:48 AM Error: Response timeout: CAN addr 51, req type 6018, RID=17
9/21/2021, 7:14:47 AM Error: Response timeout: CAN addr 51, req type 6041, RID=15
9/21/2021, 7:14:43 AM M98 P"config.g"
HTTP is enabled on port 80
FTP is disabled
TELNET is disabled
Again channel 51 is disconnected

supertb1

@t3p3tony
G4 S3 ;wait for expansion boards to start
M569.1 P50.0 T2 C5 E5:10 ; Configure the 1HCL board at CAN address 50 with a quadrature encoder on the motor shaft that has 20 steps per motor full step.
M569.M51 P51.0 S1 T2 C20 E20 R100 I0 D0 ; Configure the 1HCL board at CAN address 51 with a quadrature encoder on the motor shaft that has 20 steps per motor full step.
M569 P50.0 D4 S1 ; Configure the motor on the 1HCL at can address 50 as being in closed-loop drive mode (D4), Open loop (D2) and not reversed (S1) X axis
M569 P51.0 D2 S1 ; Configure the motor on the 1HCL at can address 51 as being in closed-loop drive mode (D4), Open loop (D2) and not reversed (S1) Y axis
M569 P0.0 S1 ; physical drive 0.0 goes forwards Z 1-2 axis

T3P3Tony

@supertb1 sorry I should have been clearer. After start up send the following from the console:

M569 P50.0 D4 S1
M569.6 P50.0 V31

supertb1

@lirwin17
since the change on the M569.1 line to P50.0 T2 C5 E5:10
I am now getting closed loop enabled : yes
on P50 V8 it is saying that the drive has an incorrect polarity
V32 made the drive run off to the end of it's travel
M569.6 P50.0 V64
Warning: No new tuning errors have been found, but some existing tuning errors exist. The drive has not been zeroed. The drive has not had it's polarity checked. The drive has not had it's control checked. The encoder has not had it's count per revolution and V128 is the same result

supertb1

@t3p3tony said in Duet3D 1HCL - Closed Loop Controller Beta test:

M569.6 P50.0 V31

M569.6 P50.0 V31
Warning: M569.6: One or more tuning errors occurred. The drive has been found to have an incorrect polarity.

supertb1

@t3p3tony does this mean that I need to switch the positive and negative wires?

T3P3Tony

@supertb1 try the following:

~~M569 P50.0 D4 S0~~

Sorry that was wrong. I forgot you have the motor moving the correct way in open loop mode.

@lirwin17 is the polarity error an encoder polarity? in which case switching A and B phases of the encoder would be right?

lirwin17

@supertb1

does this mean that I need to switch the positive and negative wires?

Sorry, this error message is a bit misleading - I'll change that. The polarity should be detected automatically, so a better error message may be "encoder polarity failed to be detected"

Please could you follow the same instructions I gave to maxgyver above (here), although on the 'movement' checkboxes down the right hand side, please could you check 'polarity detection'

We should then be able to take a look at the graph and see what's going on

supertb1

@lirwin17 50_2021-09-21_15.04.43.csv

supertb1

@lirwin17 is there another report with different variables I need to run for more information?

supertb1

@lirwin17 50_2021-09-21_15.57.09.csv

supertb1

@lirwin17 I'm not sure how to read these... it looks like coil A is out of step phase and coil B doesn't appear to be doing anything... target motor steps says there are 4 errors

lirwin17

@supertb1

is there another report with different variables I need to run for more information?

No, this is great

I'm not sure how to read these...

There's docs coming soon, but for now I'll talk you through it

The first thing to say is that the raw encoder reading is 0 on both recordings - this means it doesn't seem to register the encoder as moving at all.
This is strange because I thought that you did M122 twice after manually turning a full rotation and the encoder's reading changed... Please could you confirm this is still the case
(See this post for more detailed information)

lirwin17

@maxgyver thank you for the update! Don't worry, I've not forgotten about increasing the max speed - it's actually next on my list!

was able to increase my acceleration and jerk significantly

Excellent that's what we like to hear

I have two motors on my Y axis. They are both wired to one 1HCL board, but only one has an encoder. It calibrates fine, and I did not spot a significant problem during printing. Only the recorded graphs were of no use on this axis (at least for me). Maybe something to keep in mind for future development

Hmm okay do you mean that both motors are wired into the single driver output on the 1HCL? What exactly were the issues you were having with the recorded graph?

Furthermore, I have the impression that the drivers run in full step without any microstepping as soon as I switch to closed loop. It sounds very much like my very first printer. The prints also show a strong stepping pattern.

This is an interesting one haha - so with closed loop, we kinda lose all sense of microstepping, since the motors no longer move in discrete steps, but move as close to continuously as possible. This means that in theory, the microstepping is infinite... but the keyword here is 'continuously as possible', in reality the motor has to move some discrete distance per PID iteration, and this is a function of the frequency of the PID loop (constant) and the speed of the move (variable). If you do a very slow move, I'd expect you to be getting very small discrete moves per PID cycle (the equivalent of very high mocrostepping), whereas if we're pushing the boundary on how fast we can move, you'll get very large discrete moves per PID cycle (up to a full step).
You can actually measure the size of these discrete steps by taking a recording (with speed set to 'as fast as possible') and looking at the step phase variable, and the vertical distance between datapoints. A distance of 90 degrees means 1 step, you could work out an 'effective microstepping' from this, since you know the increments in which the motor moves.

The good news is though, as we increase the maximum speed, the 'effective microstepping' will also increase as well, so hopefully you'll see less of the stepping pattern as we do so

supertb1

@lirwin17 M122 B50
Diagnostics for board 50:
Duet EXP1HCL firmware version 3.4.0beta3+1 (2021-09-14 15:07:31)
Bootloader ID: SAME5x bootloader version 2.4beta (2021-07-23)
Never used RAM 51472, free system stack 2592 words
Tasks: Move(notifyWait,0.0%,160) HEAT(notifyWait,0.0%,95) CanAsync(notifyWait,0.0%,70) CanRecv(notifyWait,0.0%,81) CanClock(notifyWait,0.0%,72) TMC(notifyWait,38.1%,344) CLSend(notifyWait,0.0%,148) CLData(notifyWait,0.0%,142) MAIN(running,59.9%,408) IDLE(ready,0.0%,39) AIN(notifyWait,2.0%,265), total 100.0%
Last reset 00:01:25 ago, cause: power up
Last software reset time unknown, reason: HardFault bfarValid precise, available RAM 51580, slot 2
Software reset code 0x0060 HFSR 0x40000000 CFSR 0x00008200 ICSR 0x00430803 BFAR 0x20030008 SP 0x2001eba8 Task MAIN Freestk 531 ok
Stack: 00000000 00000000 00000002 20030000 00030f39 0001b8f9 0001ea4c 41000000 bf800000 00000000 533c0605 04001200 a8888700 06420000 c2010829 19a21029 50708239 5d000040 2a60041c 54540122 04801201 41200000 41c27924 4142a3fe 20000010 0002699b 00000002
Closed loop enabled: yes, live status: 0x4, encoder type rotaryQuadrature, pre-error threshold: 5.000000, error threshold: 10.000000, reverse polarity: no, tuning: 0, tuning error: 0x1f, position 0, raw count = 0, collecting data: no, ultimateGain=0.000000, oscillationPeriod=0.000000, Control loop runtime (ms): min=0.000000, max=0.066667, avg=0.008000, Control loop frequency (Hz): min=7075.472168, max=18292.683594, avg=15625.000977
Driver 0: pos 0, 106.5 steps/mm, standstill, reads 8610, writesMoves scheduled 0, completed 0, in progress 0, hiccups 0, step errors 0, maxPrep 0, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter -4/3, peak Rx sync delay 179, resyncs 0/0, no step interrupt scheduled
VIN: 24.3V, V12: 12.2V
MCU temperature: min 23.1C, current 25.4C, max 25.4C
Ticks since heat task active 157, ADC conversions started 84048, completed 84047, timed out 0, errs 0
Last sensors broadcast 0x00000000 found 0 162 ticks ago, loop time 0
CAN messages queued 728, send timeouts 0, received 744, lost 0, free buffers 37, min 37, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0

Disconnected the motor coils and turn the motor by hand one full revolution by hand:
M122 B50
Diagnostics for board 50:
Duet EXP1HCL firmware version 3.4.0beta3+1 (2021-09-14 15:07:31)
Bootloader ID: SAME5x bootloader version 2.4beta (2021-07-23)
Never used RAM 51472, free system stack 2580 words
Tasks: Move(notifyWait,0.0%,160) HEAT(notifyWait,0.0%,95) CanAsync(notifyWait,0.0%,70) CanRecv(notifyWait,0.0%,81) CanClock(notifyWait,0.0%,72) TMC(notifyWait,38.4%,344) CLSend(notifyWait,0.0%,148) CLData(notifyWait,0.0%,142) MAIN(running,59.6%,380) IDLE(ready,0.0%,39) AIN(notifyWait,2.0%,265), total 100.0%
Last reset 00:05:31 ago, cause: power up
Last software reset time unknown, reason: HardFault bfarValid precise, available RAM 51580, slot 2
Software reset code 0x0060 HFSR 0x40000000 CFSR 0x00008200 ICSR 0x00430803 BFAR 0x20030008 SP 0x2001eba8 Task MAIN Freestk 531 ok
Stack: 00000000 00000000 00000002 20030000 00030f39 0001b8f9 0001ea4c 41000000 bf800000 00000000 533c0605 04001200 a8888700 06420000 c2010829 19a21029 50708239 5d000040 2a60041c 54540122 04801201 41200000 41c27924 4142a3fe 20000010 0002699b 00000002
Closed loop enabled: yes, live status: 0x4, encoder type rotaryQuadrature, pre-error threshold: 5.000000, error threshold: 10.000000, reverse polarity: no, tuning: 0, tuning error: 0x1f, position 4055, raw count = 4055, collecting data: no, ultimateGain=0.000000, oscillationPeriod=0.000000, Control loop runtime (ms): min=0.006667, max=0.086667, avg=0.008000, Control loop frequency (Hz): min=6756.756836, max=16304.347656, avg=15625.000977
Driver 0: pos 0, 106.5 steps/mm, standstill, reads 0, wriMoves scheduled 0, completed 0, in progress 0, hiccups 0, step errors 0, maxPrep 0, maxOverdue 0, maxInc 0, mcErrs 0, gcmErrs 0
Peak sync jitter -3/4, peak Rx sync delay 183, resyncs 0/0, no step interrupt scheduled
VIN: 24.3V, V12: 12.2V
MCU temperature: min 23.1C, current 26.3C, max 26.5C
Ticks since heat task active 205, ADC conversions started 324949, completed 324948, timed out 0, errs 0
Last sensors broadcast 0x00000000 found 0 210 ticks ago, loop time 0
CAN messages queued 2005, send timeouts 0, received 2218, lost 0, free buffers 37, min 37, error reg 0
dup 0, oos 0/0/0/0, bm 0, wbm 0, rxMotionDelay 0

supertb1

@lirwin17 it is reading the encoder... raw count 4055 from zero.. .and it is a 4000 count encoder

supertb1

@lirwin17 what would be the next step to trouble shoot

lirwin17

@supertb1 hmm okay so it looks like the encoder is working...

Perhaps that reading of 0 is correct - is the motor actually moving at all during the recording?

If it's not, please could you check that the motor works in open loop mode - i.e. boot up the board and then run M569 P50.0 D3, and try to home the motor, move it, etc

If it doesn't work in open loop mode, it's most likely an issue with the wiring, you could try plugging the motor into your main board and check that it works in there

supertb1

@lirwin17 I disconnected the motor and ran it from a separate stepper drive I have built from an Arduino and a A4988.. The motor works fine in both directions outside the system, I then reconnected the motor to the drive on the 1HCL took it out of close loop mode and homed the axis, moved the motor around.. with the M569 p50.0 D3 it seams as though it cut my steps in half and is making the motor oscillate loudly, but it moves. With the closed loop off the motor also oscillates but it does move.50_2021-09-22_10.54.21.csv
Not sure what has happened but I ran a step maneuver and the drive moved about 5mm and returned some interesting results... let me know what you think