Trying my first cut with the JSTs and 0.84.2 and it failed about half way through. Got the motor current threshold 4000 then an encoder read failure, all for the TR motor. Going to try the cut again, but any ideas about how to hunt this issue down would be helpful.
Maslow-serial (3).log (4.8 KB)
Serial Messages
Index.html Version: 0.84
[MSG:INFO: Channel auto report interval set to 50 ms]
[MSG:INFO: FluidNC v0.84 (Project-and-account-for-arm-stiffness--4077508a-dirty)]
[MSG:INFO: Compiled with ESP32 SDK:v4.4.7-dirty]
[MSG:INFO: Local filesystem type is littlefs]
[MSG:INFO: Configuration file:maslow.yaml]
[MSG:INFO: Machine Maslow S3 Board]
[MSG:INFO: Board Maslow]
[MSG:INFO: UART1 Tx:gpio.1 Rx:gpio.2 RTS:NO_PIN Baud:115200]
[MSG:INFO: SPI SCK:gpio.12 MOSI:gpio.11 MISO:gpio.13]
[MSG:INFO: SD Card cs_pin:gpio.10 detect:NO_PIN freq:8000000]
[MSG:INFO: Stepping:Timed Pulse:4us Dsbl Delay:0us Dir Delay:0us Idle Delay:240ms]
[MSG:INFO: Axis count 3]
[MSG:INFO: Axis X (-2438.400,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: Axis Y (-1219.200,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: Axis Z (-100.000,0.000)]
[MSG:INFO: Motor0]
[MSG:INFO: tmc_2209 UART1 Addr:0 Step:gpio.15 Dir:gpio.16 Disable:NO_PIN R:0.110]
[MSG:INFO: Motor1]
[MSG:INFO: tmc_2209 UART1 Addr:1 Step:gpio.46 Dir:gpio.38 Disable:NO_PIN R:0.110]
[MSG:INFO: Z Axis driver test passed]
[MSG:INFO: Z2 Axis driver test passed]
[MSG:INFO: Kinematic system: Cartesian]
[MSG:INFO: Using spindle NoSpindle]
[MSG:INFO: Connecting to STA SSID:The Green House]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting..]
[MSG:INFO: Connected - IP is 192.168.0.127]
[MSG:INFO: WiFi on]
[MSG:INFO: Start mDNS with hostname:http://maslow.local/]
[MSG:INFO: SSDP Started]
[MSG:INFO: HTTP started on port 80]
[MSG:INFO: Telnet started on port 23]
Jog: Z10
Jog: X100
[MSG:INFO: Tool No: 2]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Encoder read failure on Top Right]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 1 times in the last second]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -26.539mm Counter: 1]
[MSG:WARN: Previous error was -26.539mm]
[MSG:INFO: Reset during file job at line: 687]
[MSG:ERR: Emergency stop. Update function not being called enough.1002ms since last call]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -24.447mm Counter: 2]
[MSG:WARN: Previous error was -24.447mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 18.775mm Counter: 1]
[MSG:WARN: Previous error was 18.775mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -24.408mm Counter: 3]
[MSG:WARN: Previous error was -24.408mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 18.736mm Counter: 2]
[MSG:WARN: Previous error was 18.736mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 26.608mm Counter: 1]
[MSG:WARN: Previous error was 26.608mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -24.370mm Counter: 4]
[MSG:WARN: Previous error was -24.370mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 18.697mm Counter: 3]
[MSG:WARN: Previous error was 18.697mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 26.644mm Counter: 2]
[MSG:WARN: Previous error was 26.644mm]
[MSG:WARN: Position error on Bottom Right axis exceeded 15mm while running. Error is -25.991mm Counter: 1]
[MSG:WARN: Previous error was -25.991mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -24.323mm Counter: 5]
[MSG:WARN: Previous error was -24.323mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 18.648mm Counter: 4]
[MSG:WARN: Previous error was 18.648mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 26.690mm Counter: 3]
[MSG:WARN: Previous error was 26.690mm]
[MSG:WARN: Position error on Bottom Right axis exceeded 15mm while running. Error is -26.052mm Counter: 2]
[MSG:WARN: Previous error was -26.052mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is -17.910mm Counter: 6]
[MSG:WARN: Previous error was -17.910mm]
[MSG:ERR: Emergency stop! Stopping all motors]
[MSG:WARN: The machine will not respond until turned off and back on again]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
hot glue the connectors in place on both the main board and the encoder.
David Lang
Wasn’t the whole point of the JSTs that you don’t need to do that?
Kyle wrote:
Wasn’t the whole point of the JSTs that you don’t need to do that?
yes, sorry, I didn’t realize you had the JST version.
have you checked that the magnet is glued in solidly and is in the right place?
David Lang
Yeah, I checked that when I had issues with the Ethernet cables. It calibrated with the JST and firmware upgrade just fine.
Yeah, those should fix that issue. Hmm
Can you try swapping the wire from the top right encoder and a different one?
Got a few errors, including one saying I should recalibrate, so I tried and and seems to be working now? Made a successful cut without any issues. Previously I would get the same errors when jogging, so I tried that before the cut without issue.
Not really sure why a recalibration helped. When hanging the maslow some of the corners were like 5-8 mm off which seemed not great, but sub 1mm after recalibrating. I also had to re-do a cut and the first one was about 2-3 mm shorter than it should have been.
Really have no idea what happened. Hopefully it was just a wonky calibration after upgrading. FWIW the fitness finished at about 0.5 the first time and 0.66 with a recalibration. I’ll post here if any more problems surface.
Awesome! I’m glad to hear it 
Keep us posted if you get any trouble.
Unfortunately a bunch of problems when trying to run it again today.
Not really sure what to try next besides calibrating it yet again. Makes no sense why the BR and BL would be so far off when tensioning the machine. And no idea what would cause the threshold error.
Logs:
Maslow-serial (5).log (2.3 KB)
Maslow-serial (6).log (5.1 KB)
That looks like at least your BR arm is not moving smoothly. it could be that the bolts clamping it together are too tight, it could be that the motor is too close to the idler, it could be that the idler isn’t moving on it’s shaft smoothly
if the arms do not retract cleanly, then during calibration you can run into problems because the belts are not really tight as it’s trying to take measurements.
The sled lifting can be helped by making the sled slicker (waxing the bottom for example), or by tilting the frame back to it’s closer to horizontal.
I made sure that the gears had slack and moved freely when I re assembled the arms. When I extend the belts, it doesn’t have any extra resistance — I’d think you’d feel if it was a resistance thing. Retraction works just fine as well. Suppose I might have to pull it apart again, but I really don’t want to do that again…
Sled lifting is only on the left side of the board, I think it has to do with the same issue, not dragging as it’s moving. Likely wonky a calibration.
I agree with this theory, but the question is why?
Did you notice anything funky happening during the calibration process?
How big of a grid are you running?
I stepped away when it calibrated, but it seemed to run and finish just fine. Ran a 9X9 grid and didn’t really change anything after the JST upgrade. I uploaded a saved maslow.yaml file instead of manually plugging in the workspace dimensions.
I wonder if it’s an issue with the maslow.yaml file, think I’ll remove it and upload a fresh copy then recalibrate before I rip the machine apart again. What’s odd is the center point deviation was like 2-6+mm so I recalibrated, then after that second calibration the belts zeroed at < 1mm and it seemed fixed, but later it went back to 2-6+mm deviation again, almost like something in the settings reverted or wasn’t saved.
I would make sure you have the new firmware with the length calculation fix
0.85,1 or later
David Lang
(or .84.1)
David Lang
I’m running 0.84.2
It’s the same problem I have.
It seems that the small movement trying to tighten the belt when Z moves, makes the center of the TR motor come out a little and the U pin that holds it rubs against the base on the arm and slows it down, I already removed all this part from my 4 arms and I’m not entirely sure but I do think it’s improved (or at least it doesn’t show the 4k error so often) but I need to do more tests.
I also have two off-center motors (in my case TL and BR with 2 and 5mm) and I haven’t been able to change that, I have the .84-2 version and I tried to update to the .85 but I couldn’t, it doesn’t get into shape, in the calibration at each point there’s a shaking tug-of-war and it doesn’t tighten all the belts, so I went back to the .84-2 with my old yaml, but when I release and apply tension the tug-of-war remains shaky for a moment
Quick update here, was calibrating yesterday and noticed a bump in the belt spool. Upon further inspection I found the motor gear set screw… Really glad it didn’t fall on the floor otherwise I would have had no idea. Anyway, clearly need to fix that and recalibrate — hopefully this is what was causing my issues. I’ll report back when I get it repaired.