Extrusion fail

CrazyJane

My setup:
Duet 2 Wifi
Firmware 2.03beta2
Wifi Server 1.23beta1
Web interface 1.22.6

Nozzle 0.4mm
Material 1.75 PLA
Temp 205 deg C
Bed Temp 55 deg C
Layer thickness 0.15
Config.g:
; General preferences
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

; Network
M550 P"Duet 2 Wifi / Hictop" ; Set machine name
M552 S1 ; Enable network

M586 P0 S1 ; Enable HTTP
M586 P1 S0 ; Disable FTP
M586 P2 S0 ; Disable Telnet

; Drives
M569 P0 S1 ; Drive 0 goes forwards
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S0 ; Drive 2 goes forwards
M569 P3 S1 ; Drive 3 goes forwards
;M569 P4 S1 ; Drive 4 goes forwards
M350 X16 Y16 Z16 E16 I1 ; Configure microstepping with interpolation
M92 X80.00 Y80.00 Z397.1599 E98.61 ; Set steps per mm Z406.954
M566 X900.00 Y900.00 Z12.00 E120.00 ; Set maximum instantaneous speed changes (mm/min)
M203 X6000.00 Y6000.00 Z180.00 E1200.00 ; Set maximum speeds (mm/min)
M201 X500.00 Y500.00 Z20.00 E250.00 ; Set accelerations (mm/s^2)
M906 X800.00 Y800.00 Z300.00 E800.00 I30 ; Set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

; Axis Limits
M208 X0 Y0 Z0 S1 ; Set axis minima
M208 X220 Y270 Z200 S0 ; Set axis maxima

; Endstops
M574 X1 Y1 S0 ; Set active high endstops
M558 P5 X0 Y0 Z1 H5 F120 T6000 ; Set Z probe type to switch, the axes for which it is used and the probe + travel speeds
;G31 P50 X0 Y0 Z0 ; Set Z probe trigger value, offset and trigger height
;M557 X10:220 Y10:130 S30 ; Define mesh grid

; levelling screws
M669 K0 ; Cartesian Kinematics
M671 X-26:195:195:-26 Y170:170:0:0 P0.5 ; Adjusting screws Pitch 0.5mm

; Z-Probe
G29 S1
M574 Z1 S2 ; Set endstops controlled by probe
M558 P5 H5 F1200 T6000 I1 ; Set Z probe type to modulated and the dive height + speeds
M558 P1 I1 Z1.4622 R0.4 F400
G31 X22 Y0 Z1.4622 p600
M557 X22:180 Y0:250 S30 ; Define mesh grid

; 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 P2T100000 B4725 C7.060000e-8 R4700 ; Set thermistor + ADC parameters for heater 1
M143 H2 S285 ; Set temperature limit for heater 1 to 285C

; Fans
M106 P0 S0.3 I0 F500 H-1 ; Set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned off
M106 P1 S1 I0 F500 H1 T45 ; Set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned on

; Tools
M563 P0 D0 H2 ; Define tool 0
G10 P0 X0 Y0 Z0 ; Set tool 0 axis offsets
G10 P0 R0 S0 ; Set initial tool 0 active and standby temperatures to 0C

I've recently converted from a direct to a Bowden drive on my Cartesian printer, and loaded the current firmware at the same time.
After calibration the printer appears to perform correctly, however on a number of jobs the filament has stopped extruding after a time. No error is reported and the nozzle is not blocked. Halting the job and immediately manually extruding filament functions correctly.
The new drive uses the original motor and wiring which appears to be correctly installed, The extruder is a genuine E3D V6 with a titanium thermal break

Any help or suggestions would be much appreciated

Edgars Batna

@crazyjane You might wanna remove the password to your Wifi from the post...

Also, post a sample gcode where this happens. Preferably just the layers or moves where it actually happens.

You might wanna try increasing E microsteps to 256 and see how that affects the behavior. The motor might need more juice tho.

CrazyJane

@edgars-batna
Thanks for your reply. I feel like a fool for not realising that the password was displayed - fixed.

I think I might have found the solution, I changed the slicing program from Simplify3D to CURA 4 and, so far, the parts that were failing are printing correctly, fingers crossed. I will do a detailed inspection of both G-code files to try to see what went wrong.

Your comments on the microstepping have left me slightly confused. I understood that M350 ... E16 I1was the recommended method for enabling microstepping interpolation, am I mistaken?

Veti

a titanium thermal break might be the wrong one for pla.

this can cause clogging. since you are not using a geared extruder, the extruder can be to weak to overcome this.

also where did you get Z397.1599 from? that seems like a very unusual number

Edgars Batna

@crazyjane said in Extrusion fail:

Your comments on the microstepping have left me slightly confused. I understood that M350 ... E16 I1was the recommended method for enabling microstepping interpolation, am I mistaken?

Depending on the slicer there will be completely different paths in the gcode. Problems are known on lower steps per mm due to rounding errors in combination with tiny extrusion segments. I know for a fact that Slic3r PE likes to sprinkle the gcode with tiny extrusion segments on curves which upsets the firmware. This then causes a problem like you describe on my printer with otherwise very similar steps per mm.

There are multiple things that I did to alleviate, but not solve this. One of the things included increasing E steps to 256. Are you using pressure advance by chance?

dc42

@edgars-batna said in Extrusion fail:

Problems are known on lower steps per mm due to rounding errors in combination with tiny extrusion segments.

That was corrected several firmware versions ago. However, I still recommend increasing microstepping if the extruder steps/mm would other be below about 400, especially if you use smaller than usual nozzles or layer heights.

Edgars Batna

@dc42 I'm aware of the fixes, but there's still an outstanding, reproducible issue as per my "PA issue?" thread which you already put on the todo list. Even if I set steps per mm to 256, there are cases when step pulses are wrong, but I don't want to repeat a 60 page thread again.

dc42

@edgars-batna said in Extrusion fail:

@dc42 I'm aware of the fixes, but there's still an outstanding, reproducible issue as per my "PA issue?" thread which you already put on the todo list. Even if I set steps per mm to 256, there are cases when step pulses are wrong, but I don't want to repeat a 60 page thread again.

Please can you give me a link to that thread, because I haven't found it using the forum search facility or by listing your posts.

Phaedrux

@dc42 I think it's this one
https://forum.duet3d.com/topic/8672/extruder-motors-skip-steps-with-pressure-advance-enabled/65

dc42

@phaedrux said in Extrusion fail:

@dc42 I think it's this one
https://forum.duet3d.com/topic/8672/extruder-motors-skip-steps-with-pressure-advance-enabled/65

If it's that one then it's still on my list to investigate as part of the development of firmware 2.03.

Edgars Batna

@dc42 Yes, it's that one.