RepRapFirmware 3.6.0-alpha.4+3 available for testing

o_lampe

@balajiramani Thanks for being so persistent, posting your calibration issues. It's a huge relieve for me, @dc42 found a solution.
I wondered if it was related to the, IHMO pretty huge endstop differences?

8/31/2024, 5:58:57 PM	M666
                        Endstop adjustments X-1.26 Y-1.03 Z2.30, tilt X0.00% Y0.00%

dc42

@Notepad I think the Push and Pop errors are happening because you are still running version 3.5.2 of Duet Control Server.

balajiramani

@o_lampe I think how @dc42 interacts with the community and listens to each one of us, is what makes the whole Duet ecosystem amazing!

While the endstop values are high, I don't think it is related to that. @dc42 what do you think?

Thanks,
Balaji

dc42

@balajiramani it wasn't relayed to the endstop adjustments. The code to segment automatically-generated moves didn't always work.

Aurimas

@dc42
got this error
Error: Movement halted because a step timing error occurred (code 3). Please reset the controller.

here is M122

=== Diagnostics ===
RepRapFirmware for Duet 3 Mini 5+ version 3.6.0-alpha.4+3 (2024-08-28 10:03:49) running on Duet 3 Mini5plus WiFi (standalone mode)
Board ID: 44BBP-1N6KL-K65J0-409N2-1BW1Z-RD9N1
Used output buffers: 3 of 40 (40 max)
=== RTOS ===
Static ram: 92328
Dynamic ram: 91792 of which 12 recycled
Never used RAM 37808, free system stack 121 words
Tasks: NETWORK(2,nWait 7,11.6%,183) HEAT(3,nWait 6,0.0%,325) Move(4,invalid,0.1%,247) TMC(4,nWait 6,0.9%,65) CanReceiv(6,nWait 1,0.1%,771) CanSender(5,nWait 7,0.0%,327) CanClock(7,delaying,0.0%,348) MAIN(1,running,86.4%,639) IDLE(0,ready,0.1%,29) AIN(4,delaying,0.8%,255), total 100.0%
Owned mutexes: WiFi(NETWORK)
=== Platform ===
Last reset 19:56:34 ago, cause: software
Last software reset at 2024-08-03 12:45, reason: HardFault imprec, Gcodes spinning, available RAM 12036, slot 0
Software reset code 0x4063 HFSR 0x40000000 CFSR 0x00000400 ICSR 0x00489803 BFAR 0xe000ed38 SP 0x200120a0 Task NETW Freestk 544 ok
Stack: 00000000 000aff28 200014ec 2000dfe0 ffffffff 0009e9c7 00012156 210f0000 00012179 2000dfe0 00000000 000afea8 00000083 e000e000 2001e880 a5a5a5a5 000121ed 200355f8 00000000 563bc5f2 00031c25 2001e880 2001ce00 00000001 200355f8 00000000 00033dd7
Error status: 0x04
Aux0 errors 0,0,0
MCU temperature: min 22.3, current 30.3, max 31.2
Supply voltage: min 24.3, current 24.4, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
Heap OK, handles allocated/used 99/4, heap memory allocated/used/recyclable 2048/420/316, gc cycles 0
Events: 0 queued, 0 completed
Date/time: 2024-09-03 09:16:25
Slowest loop: 246.24ms; fastest: 0.09ms
=== Storage ===
Free file entries: 18
SD card 0 detected, interface speed: 22.5MBytes/sec
SD card longest read time 12.1ms, write time 94.0ms, max retries 0
=== Move ===
Segments created 667, maxWait 66447882ms, bed comp in use: mesh, height map offset 0.000, hiccups added 0 (0.00/278.36ms), max steps late 1, ebfmin 0.00, ebfmax 0.00
Pos req/act/dcf: 34659.00/34449/0.28 -5056.00/-4998/-0.90 15480.00/15286/0.68
no step interrupt scheduled
Driver 0: standstill, SG min 0, read errors 0, write errors 1, ifcnt 33, reads 42543, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 1: standstill, SG min 0, read errors 0, write errors 1, ifcnt 33, reads 42543, writes 20, timeouts 0, DMA errors 0, CC errors 0
Driver 2: standstill, SG min 0, read errors 0, write errors 1, ifcnt 37, reads 42540, writes 22, timeouts 0, DMA errors 0, CC errors 0
Driver 3: standstill, SG min 0, read errors 0, write errors 1, ifcnt 37, reads 42540, writes 22, timeouts 0, DMA errors 0, CC errors 0
Driver 4: standstill, SG min 0, read errors 0, write errors 1, ifcnt 25, reads 42551, writes 12, timeouts 0, DMA errors 0, CC errors 0
Driver 5: not present
Driver 6: not present
=== DDARing 0 ===
Scheduled moves 113330, completed 113290, LaErrors 0, Underruns [0, 0, 0]
=== DDARing 1 ===
Scheduled moves 0, completed 0, LaErrors 0, Underruns [0, 0, 0]
=== Heat ===
Bed heaters 0 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
Heater 0 is on, I-accum = 0.0
Heater 1 is on, I-accum = 0.0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 3
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is doing "M106 P5 S0.1" in state(s) 0 0, running macro
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 1, axes/extruders owned 0x0000807
Queue 0 has 'M106 P5 S0.1' for move 113291
Queue 0 has 'M106 P5 S0.1' for move 113293
Queue 0 has 'M106 P5 S0.1' for move 113299
Queue 0 has 'M106 P5 S0.1' for move 113300
Queue 0 has 'M106 P5 S0.1' for move 113303
Queue 0 has 'M106 P5 S0.1' for move 113308
Queue 0 has 'M106 P5 S0.1' for move 113309
Queue 0 has 'M106 P5 S0.1' for move 113311
Queue 0 has 'M106 P5 S0.1' for move 113312
Queue 0 has 'M106 P5 S0.1' for move 113314
Queue 0 has 'M106 P5 S0.1' for move 113317
Queue 0 has 'M106 P5 S0.1' for move 113325
Queue 0 has 'M106 P5 S0.1' for move 113328
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 755848, received 2872555, lost 0, ignored 0, errs 0, boc 0
Longest wait 5ms for reply type 4014, peak Tx sync delay 282, free buffers 26 (min 25), ts 358975/358974/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 223.95ms; fastest: 0.00ms
Responder states: MQTT(0) HTTP(0) HTTP(1) HTTP(0) HTTP(0) FTP(0) Telnet(0)
HTTP sessions: 2 of 8
=== WiFi ===
Interface state: active
Module is connected to access point 
Failed messages: pending 0, notrdy 0, noresp 0
Firmware version 2.1.0
MAC address c4:5b:be:ce:9c:81
Module reset reason: Power up, Vcc 3.36, flash size 2097152, free heap 36344
WiFi IP address 192.168.1.131
Signal strength -52dBm, channel 6, mode 802.11n, reconnections 0
Clock register 00002001
Socket states: 5 0 3 0 0 0 0 0

jay_s_uk

@Aurimas see the above links for alpha 5+1

MaxGyver

@dc42

I just tested 3.6.0-alpha.5+1 on our 5meter printer. The "homing jolt" on our CAN-connected Servo Drives is strong enough to make the servo drives go into fault mode Reducing the homing speed by 50% did help, but it still produces a loud "clonk"

Everything else is working as expected
Setup: Duet MB6HC+ 3xEXP1XD+ EXP3HC

My small printer is flawlessly printing since an on our under 3.6.0-alpha.5+1
Setup: Duet MB6HC+ 3xEXP1HCL+TOOL1RR

four screw bed tramming and mesh probing with the SZP seems to be working as expected, I only had to reduce the pressure advance value by 50%.
I have noticed some short movement pauses during printing, these were also present in RRF 3.5.2, maybe increasing the movement queue length can help here?

dc42

@MaxGyver thanks for your report. Fixing the homing jolt is one of the remaining things we need to do before we release beta 1.

You can lengthen the movement queue yourself using the M595 command.

edsped

@dc42 I'm starting to get random tool drops when picking up and when parking tools, maybe once every 20 or so toolchanges. Attached are what I believe to be pertinent files... It happens with all tools and has never happened prior to this alpha and have hundreds of hours on the printer. No other code changes were made other than the alpha update.

9/5/2024, 8:21:22 PM	M122
=== Diagnostics ===
RepRapFirmware for Duet 3 MB6HC version 3.6.0-alpha.4 (2024-08-13 15:11:47) running on Duet 3 MB6HC v1.02 or 1.02a (standalone mode)
Board ID: 08DJM-9P63L-DJ3T8-6J1F2-3SS6J-KA6VB
Used output buffers: 3 of 40 (29 max)
=== RTOS ===
Static ram: 133840
Dynamic ram: 128776 of which 24 recycled
Never used RAM 53240, free system stack 120 words
Tasks: NETWORK(1,ready,33.0%,171) ETHERNET(5,nWait 7,0.2%,316) HEAT(3,nWait 6,0.0%,323) Move(4,nWait 6,1.8%,209) TMC(4,nWait 6,8.5%,53) CanReceiv(6,nWait 1,0.1%,769) CanSender(5,nWait 7,0.1%,325) CanClock(7,delaying,0.0%,348) MAIN(1,running,56.1%,103) IDLE(0,ready,0.0%,29), total 100.0%
Owned mutexes:
=== Platform ===
Last reset 01:14:12 ago, cause: power up
Last software reset at 2024-08-16 08:29, reason: User, Gcodes spinning, available RAM 62232, slot 0
Software reset code 0x0003 HFSR 0x00000000 CFSR 0x00000000 ICSR 0x0044a000 BFAR 0x00000000 SP 0x00000000 Task MAIN Freestk 0 n/a
Error status: 0x00
Aux0 errors 0,0,0
MCU temperature: min 10.2, current 31.1, max 31.2
Supply voltage: min 24.1, current 24.2, max 24.5, under voltage events: 0, over voltage events: 0, power good: yes
12V rail voltage: min 11.9, current 12.2, max 12.5, under voltage events: 0
Heap OK, handles allocated/used 99/4, heap memory allocated/used/recyclable 2048/304/256, gc cycles 0
Events: 0 queued, 0 completed
Date/time: 2024-09-05 20:21:21
Slowest loop: 219.48ms; fastest: 0.07ms
=== Storage ===
Free file entries: 20
SD card 0 detected, interface speed: 25.0MBytes/sec
SD card longest read time 42.0ms, write time 10.7ms, max retries 1
=== Move ===
Segments created 534, maxWait 908262ms, bed comp in use: mesh, height map offset 0.000, hiccups added 0 (0.00ms), max steps late 0, ebfmin 0.00, ebfmax 0.00, mcet 0.024
Pos req/act/dcf: 0.00/1/-0.93 0.00/-1/0.98 157600.00/157599/1.00 0.00/0/0.00
no step interrupt scheduled
Driver 0: standstill, SG min 0, mspos 532, reads 42260, writes 26 timeouts 0
Driver 1: standstill, SG min 0, mspos 452, reads 42260, writes 26 timeouts 0
Driver 2: standstill, SG min 0, mspos 672, reads 42260, writes 26 timeouts 0
Driver 3: standstill, SG min 0, mspos 136, reads 42257, writes 30 timeouts 0
Driver 4: standstill, SG min 0, mspos 600, reads 42257, writes 30 timeouts 0
Driver 5: standstill, SG min 0, mspos 760, reads 42257, writes 30 timeouts 0
=== DDARing 0 ===
Scheduled moves 142683, completed 142683, LaErrors 0, Underruns [0, 0, 0]
=== DDARing 1 ===
Scheduled moves 0, completed 0, LaErrors 0, Underruns [0, 0, 0]
=== Heat ===
Bed heaters 0 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1 -1, chamber heaters -1 -1 -1 -1, ordering errs 0
=== GCodes ===
Movement locks held by null, null
HTTP is idle in state(s) 0
Telnet is idle in state(s) 0
File is idle in state(s) 0
USB is idle in state(s) 0
Aux is idle in state(s) 0
Trigger is idle in state(s) 0
Queue is idle in state(s) 0
LCD is idle in state(s) 0
SBC is idle in state(s) 0
Daemon is idle in state(s) 0
Aux2 is idle in state(s) 0
Autopause is idle in state(s) 0
File2 is idle in state(s) 0
Queue2 is idle in state(s) 0
Q0 segments left 0, axes/extruders owned 0x0000000
Code queue 0 is empty
Q1 segments left 0, axes/extruders owned 0x0000000
Code queue 1 is empty
=== CAN ===
Messages queued 317944, received 356576, lost 0, ignored 0, errs 959, boc 0
Longest wait 2ms for reply type 6031, peak Tx sync delay 61219, free buffers 50 (min 49), ts 22265/22264/0
Tx timeouts 0,0,0,0,0,0
=== Network ===
Slowest loop: 176.15ms; fastest: 0.03ms
Responder states: MQTT(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) HTTP(0) FTP(0) Telnet(0) Telnet(0)
HTTP sessions: 1 of 8
= Ethernet =
Interface state: active
Error counts: 0 0 0 1 0 0
Socket states: 5 2 2 2 2 0 0 0
=== WiFi ===
Interface state: disabled
Module is disabled
Failed messages: pending 0, notrdy 0, noresp 0
Socket states: 0 0 0 0 0 0 0 0
=== Multicast handler ===
Responder is inactive, messages received 0, responses 0[tfree3.g](/assets/uploads/files/1725582328191-tfree3.g) [tool_unlock.g](/assets/uploads/files/1725582328225-tool_unlock.g) [tpost3.g](/assets/uploads/files/1725582328253-tpost3.g) [tpre3.g](/assets/uploads/files/1725582328279-tpre3.g) [TOOL-PICKUP (1).g](/assets/uploads/files/1725582328303-tool-pickup-1.g)

TOOL-PICKUP.g

M98 P"/macros/tool_lock.g" 		; Lock the toolM98 P"/macros/tool_lock.g" 	
;G92 E0

if state.currentTool = 0
	M150 E0 U0 R0 B0 W255 S2 F0 P255 ; TURN ON LED
elif state.currentTool = 1
	M150 E1 U0 R0 B0 W255 S2 F0 P255 ; TURN ON LED
elif state.currentTool = 2
	M150 E2 U0 R0 B0 W255 S2 F0 P255 ; TURN ON LED
elif state.currentTool = 3
	M150 E3 U0 R0 B0 W255 S2 F0 P255 ; TURN ON LED

if state.currentTool = 0
	M116 P0 S6
elif state.currentTool = 1
	M116 P1 S6
elif state.currentTool = 2
	M116 P2 S6
elif state.currentTool = 3
	M116 P3 S6
G4 S2

M302 P0  		          		; Prevent Cold Extrudes, just in case temp setpoints are at 0
G1 E12 F800	 				; Unretract to nozzle
G1 E6 F200      	            ; Pebble Purge
M106 S255			    	   	; Cooling 100%
G4 S3                           ; Wait 3 seconds
G53 G1 Y305 F30000              ; Retract the entire tool and wipe Backwards.
G1 R2 Z0 F24000                 ; Restore prior Z position before tool change was initiated.
                                ; Note: tool tip position is automatically saved to slot 2 upon the start of a tool change.
                                ; Restore Z first so we don't crash the tool on retraction.
G1 R0 Y0 F24000                 ; Retract tool by restoring Y position next now accounting for new tool offset.
					    		; Restoring Y next ensures the tool is fully removed from parking post.
G1 R0 X0 F24000                 ; Restore X position now accounting for new tool offset.
M106 R2                         ; restore print cooling fan speed

tpre3.g

; Runs after freeing the previous tool if the next tool is T3
; Note: tool offsets are not applied at this point!
G90                              ; Ensure the machine is in absolute mode before issuing movements.
M150 E3 U0 R255 B0 W0 S2 F0 P255 ; TURN ON LED
G1 X0.0 Y295 F24000              ; Rapid to the approach position without any current tool.
G60 S0                           ; Save this position as the reference point from which to later apply new tool offsets.

tpost3.g

; runs after firmware thinks Tool3 is selected
; Note: tool offsets are applied at this point!
; Note that commands prefixed with G53 will NOT apply the tool offset.
G90                                ; Return to absolute   
M150 E3 U255 R255 B0 W0 S2 F0 P255 ; TURN ON LED
G53 G1 Y325 F18000                 ; Rapid move to a safe Y-line when no tool is locked.
G53 G1 Y337 F1000                  ; Move to the pickup position with tool-1.
M116 P3 S4                         ; Ensure hot end is to temperature prior to pulling away from tool post.
M98 P"/macros/TOOL-PICKUP.g"       ; Lock the toolM98 P"/macros/tool_lock.g"

tfree3.g

; tfree3.g
; Runs at the start of a toolchange if the current tool is tool-3.
; Note: tool offsets are applied at this point unless we preempt commands with G53!
; ################# Tool 3 Free Prep ##################
G91                           	;Relative to move bed down
G1 Z.2 F18000                  	;Move the bed further from the nozzle prior to any tool moves. 
G90                           	;Return to absolute
; ################# Tool 3 Free #######################
G53 G1 X0.0 Y275 F24000       	;Rapid to the back of the post. Stay away from the tool rack so we don't collide with tools.
                            	;This position must be chosen such that the most protruding y face of the current tool
                             	;(while on the carriage) does not collide with the most protruding y face of any parked tool.
G1 E-12 F400						;Retract 18mm of filament to minimize oozing
;G53 G1 Y337.5 F18000        	; Controlled move to the park position with tool-0. (park_x, park_y)
G53 G1 Y335 F24000        	; Controlled move to the park position with tool-0. (park_x, park_y)
M98 P"/macros/tool_unlock.g" 	;Unlock the tool
M150 E3 U0 R0 B0 W255 S2 F0 P0  ; TURN OFF LED
G53 G1 Y300 F18000            	;Retract the pin.
M106 P6 S0						;Turn off part cooling fan

edsped

@dc42 If it occurs when picking the tool up the twist lock doesn't fully engage then the tool either falls off as it pulls away from the parking posts or flops around when printing. When dropped off it's as if the twist lock doesn't fully disengage then the tool moves with the carriage then drops as the carriage pulls away from the parking posts.

Printer is Jubilee with (4) tools MB6HC with (4) Fly-RRF's driving the extruders.

gloomyandy

@edsped What version of RRF did you have installed before you tried 3.6.0-alpha.4? I'd recommend that you do the following:

Switch back to whatever you had before and run for a while to confirm that your toolchanging is still ok. You would be surprised how often a mechanical issue shows up when you make a change to the firmware (maybe because folks do more, or something else changes).
You install the latest alpha5+1 version (see: https://forum.duet3d.com/post/344094) and test again with that.

If the old version of RRF works and the latest alpha still does not work, please post your config.g file and your tool_lock.g file.

edsped

@gloomyandy I'm thinking the same thing or the stepper is failing. The issues happen so fast and infrequently that I don't actually see it happen, only the after effects. I did see one park attempt where it looked like it attempted to pick up the tool about 2cm in front of the tool plate. I have pretty high travel speeds for my tool changes and will try lowering them first and will revert back to 3.5.2 if I still have issues and will go from there. I do have to say in the 3+ years I've been running this machine I've never had tool drop issues.

gloomyandy

@edsped If you stick with 3.6 make sure you are using the most recent release (see the link I provided above), this contains a number of fixes so that may impact your tests. You may also want to try disabling input shaping to see if that has any impact on your high speed moves as IS in 3.6 is very different to that used in 3.5 (as a result you may also need to retune your motor current if you are getting missed steps).

edsped

@gloomyandy Timing was on my side this morning... Started a print and went for cup of coffee and came back to the carriage air printing, tool was never picked up and it doesn't appear that the twist lock was ever actuated. Attached video starts at the print being paused while tool 4 was supposed to be attached and printing. Clearly the tool wasn't picked up as it should have been. When I cancelled the print the carriage went to the return position and didn't appear to fully park the tool as the two plates never made contact and the twist lock was never actuated. I'm not sure if this is something in the tool lock or unlock macro or something else, again it's an issue I've never seen before and those macros haven't been "tweaked" in ages. Twist lock moves freely and I can't do anything to make it bind FWIW...

failed pickup video

normal operation

gloomyandy

@edsped What version of RRF were you using for this test?

edsped

@gloomyandy 3.5.1 Will revert at some point this weekend or today. The issue with the tool change is that it's so random. I can have hundreds of flawless tool changes other times they'll happen in short periods and of course it's never when I'm looking. As an aside I mostly do single tool prints and sometimes will have a flawless pickup and the tool lock will not fully disengage at the end of the print and will drop the tool as the carriage retracts from the tool posts. Other times the lock will not fully engage during pickup and will drop the tool as it retracts or the tool plate won't be tight to the carriage during print and the tool will kind of flop. My initial thought was mechanical binding in the pin mechanism but the mechanism operates freely. Other thought maybe bad connector or an issue with the stepper that drives the pin that just happens to coincide with the firmware change. I have a print that I need the higher quality for so will get through it and revert and print a bunch of parts that I've been printing to see how it goes. Upside is that it will also give me a baseline to compare print quality between firmwares.

gloomyandy

@edsped So just to check you got the tool change failure with 3.5.1?

edsped

@gloomyandy Sorry to be unclear... No issues with 3.5.1 prior to updating to 3.6.0 Alpha. I've not reverted to 3.5.1 yet so can't say for certain it's a 3.6.0 thing yet only circumstantially for now. Will revert to 3.5.1 later to see if it's firmware or other issue.

edsped

@gloomyandy reverted to 3.5.1 and am ~50 tool changes in without issue... Will continue to run throughout the morning and will follow up. I'm thinking it may just be wise to zip up my configuration files and link to them if there's no issues when running 3.5.1. One thing for sure is print quality improvement is definitely noticeable..

gloomyandy

@edsped Before you do that I suggest that you test with the latest version of 3.6 (after running 3.5.1 for a while to be sure that you do not get any further problems when changing tools).