Unsolved How to get DWC to Display what line of Gcode it is on?

[Tinman]

@dc42 The behaviour of this file is even more troubling:

Tall Axle Insert Whole Job.gc

The Z axis randomly climbed by about 70mm during the facing operation and then froze. There is nothing unusual in that section of the file. This kind of behaviour is dangerous in a cnc machine. The latest RRF updates have been great however as our mill becomes more mature and our users want to run real jobs this is going to be a serious obstacle.

[OwenD]

@Tinman
Based on @dc42's comments above about the problem possibly being related to the multiple motion systems have you tried

• Removing M0 from the file (if a second motion system is getting ahead it may be stopping the job)
• If the above is true, it may also turn off the spindle when it reaches M5, so maybe remove as well
• Liberally sprinkle M400 in the code (say every 100 lines). Do this especially before your tool change.

Can't explain the lifting by 70mm unless that was part of another file that's activated by M0, Tnnn or a trigger

What's in "ManualToolChange.g" ?

[Tinman]

@OwenD I previously mentioned that if I delete the last 90% of the file it sails through the trouble section without problem. I suspect it has to do with file length. It seems too simple but I have no other theories.

[dc42]

@Tinman the file length will affect how long to takes the second file reader to find the M0 at the end of the file, or run out of file if there isn't a M0 command.

[Tinman]

@dc42 I do have an M0 at the end of the file. Compared to my 3D printer files these cnc files are quite small. Please look at the file I uploaded.

[OwenD]

This post is deleted!

[Tinman]

@dc42 Please look at my file and tell me why it crashes the board the way it does? I need to be able to support other makers and users of our Milo cnc mill and this has really got me stuck.

[Tinman]

@dc42 I uploaded the file as you requested. Still hoping you can look at it.

[Tinman]

@Phaedrux I'm part of the Millennium Mills design team. I'd be happy to show you how our Milo CNC mill works and how this specific problem is affecting efficient toolpath generation. I think you're also in Canada so I could show you live if that works. I've been avoiding further macro generation because I don't want to recommend these methods to our users if this can't be fixed.

[dc42]

@Tinman this is on my list to look at. It slipped below my radar for a while because the thread title doesn't describe the problem, or indeed suggest that there is a problem.

[Tinman]

@dc42 Indeed, it started as me trying to troubleshoot the problem myself and I wasn't able to rename it when I couldn't solve it. Please rename the thread if that's possible.

[Tinman]

@dc42 I've been wanting to do a video for the group to show "how to" do a job with tool changes but I keep delaying because nobody wants to watch me freeze up my mill. It used to work fine. I have a nagging feeling that it has to do with the extra precision now that I do multi-sampled averaged probing to set the WCS. Perhaps the extra decimal places are confusing the machine.

[AndyE3D]

@Tinman hopefully I can help getting to the cause of the issue. Please can you do 2 things for me:

• Provide you system configuration files & macros so I can try to recreate the issue
  • If you don't want to share all the config files then please share the ManualToolChange.g as it is used in the .gc files you uploaded.
• Try removing the M0 from the end of the files you have uploaded and run them again. Let me know if you still get the same freezing issue

[Tinman]

@AndyE3D Really appreciate your time on this. I have attached the manual toolchange file. My macros are admittedly not the prettiest code since they are a work in progress. We will develop final macros when the concepts are proven.

ManualToolChange.g

[Tinman]

@AndyE3D That macro also calls a macro that determines the tool length:

ToolZProbe.g

[Tinman]

@AndyE3D And before the job is run a macro is run to set the WCS to the centre top of the workpiece:

Centre Workpiece.g

[Tinman]

@AndyE3D So the order of macros is:

1. Centre Workpiece.g is run so that the WCS knows where the top centre of the workpiece is.
2. The Tall Axle Insert Whole Job.gc file is run and before milling starts and with each tool change it calls:
   a)ManualToolChange.g which then calls
   i)ToolZProbe.g

There are two sensors used.
1. a sexbolt sensor which is used to determine xyz probe length as well as tool length
2. an xyz probe mounted in the spindle for the duration of the Centre Workpiece.g process

There is also a global variable defined in config.g which is used to exchange z offset information between the Centre Workpiece.g macro and the ToolZProbe.g macro. You can see it in this file

config.g

[AndyE3D]

@Tinman I've had a look through the files and nothing is immediately obvious that would cause the issue. Do you have any triggers, a daemon.g, or any other code that may be running on the Duet/sending commands to the Duet?

Also were you able to try the print file without the M0 command at the end?

Another thing I would like you to try is to add M400 to the start of each of the macros. If it is an issue with the second file reader, this should cause them to resynchronise.

[AndyE3D]

@Tinman I have been able to reproduce similar symptons to what you have described using a much shorter gcode file. The only differences appear to be that this will cause the Duet to hang consistently at the same line in the file compared to the position changing, and the duet becomes unresponsive to gcode (except estop).

@dc42
https://github.com/Duet3D/RepRapFirmware/issues/859

AndyEveritt created this issue in Duet3D/RepRapFirmware

closed [Bug]: Duet becomes unresponsive when printing #859

[Tinman]

@AndyE3D Thanks for looking at everything. I did try with M0 removed and had the same trouble. I haven't used any triggers or daemon.g or anything fancy. I will try inserting an M400 in the macros.

In my most recent attempt at a multi toolchange file I removed the M0. Early in the job the z axis decided it wanted to dive at top speed into the workpiece. It was alarming.

As before when I take exactly the same job and break it up into individual jobs everything runs fine.