Just finished, firmware weird

Troubleshooting
1

I need some help! I did the flash firmware dance with the button…
Took it out to the garage and got it to retract.
Then extended and anchored.
I never could get it to log onto my network or to see it on the network.
BTW, the network setup page -really- need some “english” applied to it. SUPER hard to tell what is what… Could we maybe describe things as the “Maslow server”???

Initial calibration seemed to work, then the second round pulled out the upper left belt and I hit stop. After that I couldn’t get anything to work.

I’ve re-flashed at least 5 times time and I think, maybe, its working? I’m getting this memory low error and the internet connection keeps dropping off (direct maslow server).

Too much sweating and swearing in the garage, gotta take a break…

Serial Messages
Index.html Version: 1.07
[MSG:INFO: FluidNC v3.0.x (noGit)]
[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: STA SSID is not set]
[MSG:INFO: AP SSID maslow IP 192.168.0.1 mask 255.255.255.0 channel 1]
[MSG:INFO: AP started]
[MSG:INFO: WiFi on]
[MSG:INFO: Captive Portal Started]
[MSG:INFO: HTTP started on port 80]
[MSG:INFO: Telnet started on port 23]
[MSG:INFO: Channel auto report interval set to 50 ms]
Retract All
[MSG:INFO: Retracting all belts]
[MSG:INFO: Requesting state change from Unknown to Retracting Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: Bottom Right pulled tight with offset -0.011]
[MSG:INFO: Top Left pulled tight with offset 0.000]
[MSG:INFO: Top Right pulled tight with offset 0.000]
[MSG:INFO: Bottom Left pulled tight with offset 0.000]
[MSG:INFO: Requesting state change from Retracting Belts to Belts Retracted]
[MSG:INFO: Succeeded]
Stop
Release Tension
[MSG:INFO: Requesting state change from Belts Retracted to Releasing Tension]
[MSG:INFO: Cannot release tension from state Belts Retracted]
Retract All
[MSG:INFO: Retracting all belts]
[MSG:INFO: Requesting state change from Belts Retracted to Retracting Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: Top Left pulled tight with offset 0.000]
[MSG:INFO: Top Right pulled tight with offset 0.000]
[MSG:INFO: Bottom Right pulled tight with offset 0.000]
[MSG:INFO: Bottom Left pulled tight with offset 0.000]
[MSG:INFO: Requesting state change from Retracting Belts to Belts Retracted]
[MSG:INFO: Succeeded]
Stop Maslow and Gcode
[MSG:INFO: Caution: Unlocked]
Retract All
[MSG:INFO: Retracting all belts]
[MSG:INFO: Requesting state change from Belts Retracted to Retracting Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: Bottom Right pulled tight with offset 0.011]
[MSG:INFO: Top Right pulled tight with offset 0.000]
[MSG:INFO: Top Left pulled tight with offset 0.000]
[MSG:INFO: Bottom Left pulled tight with offset 0.000]
[MSG:INFO: Requesting state change from Retracting Belts to Belts Retracted]
[MSG:INFO: Succeeded]
Stop
Retract All
[MSG:INFO: Retracting all belts]
[MSG:INFO: Requesting state change from Belts Retracted to Retracting Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: Top Right pulled tight with offset 0.000]
[MSG:INFO: Bottom Left pulled tight with offset -0.011]
[MSG:INFO: Bottom Right pulled tight with offset -0.011]
[MSG:WARN: Low memory: 13884 bytes]
[MSG:WARN: Low memory: 10724 bytes]

2 Likes
2

From looking at that log all seems well, but it mostly just shows retracting the belts. What is the current state? Where are you stuck now?

3

So the low memory warning is not something to be worried about?
I wasn’t getting any action out of the unit when I pushed the buttons.

This morning I was able to extend and retract with my Android phone (that’s a MAJOR bonus!!!)

I’ll have to tackle it again later…

The force required to start the extend is -disturbingly- large. As in “popping my slightly larger than stock slotted end fittings a notch”… Is there any chance we could think this through a little more??? Its really not intuitive that you are supposed to force it that hard! It would be nice if they would spool out a little to start with (maybe an inch or so), then wait for you to pull on it. The transition from “waiting for abusive pull” to “starting and stopping as you gently pull” is really wierd.

Could this screen get a LOT more clarity? Its seriously confusing.

image
image475×893 80.1 KB

Maybe:
Define ESP (Maslow brain) role/connection order:

What access point (WiFi network) does the ESP (Maslow brain) need to be connected to:

[FYI, the scan button does not actually fill in this box… And its not clear whats supposed to happen]

Password to join access point (WiFi network)

[Add a double grey line here to make it CLEAR these are different things]

What is the ESP (Maslow brain) internal access point SSID (WiFi network name)

Password for ESP (Maslow brain) internal access point

4

Are you using the rocking motion to get them started? It shouldn’t take that much force.

The firmware is based on FluidNC which has a lot of different screens some of which are better than others. I’d recommend giving the user guide a read through for a quick walthrough of how to set things up:

5

Bar,

Yes, I am using the rocking motion. The belt tension generated by this is BIG. I’ll use a force gauge on it the next time I power up. I’ve printed some “stock” slot width belt ends (I’ve got 14mm mounting bolts in the garage floor).

1 Like
6

It shouldn’t take that much force, I can get mine started extending using just one finger and a thumb by rocking it and then once it’s started it should require almost no force to pull the belts out

7

Interesting! Mine requires scary levels of force. I’ll measure it tonight.

1 Like
8

Yeah, that sounds wrong. Is it all four arms or just one that is like that?

9

All of them behave the same.

1 Like
11

Can you get a video of it happening? I haven’t seen that before

12

Bar wrote:

It shouldn’t take that much force, I can get mine started extending using just
one finger and a thumb by rocking it and then once it’s started it should
require almost no force to pull the belts out

I’ve found that it sometimes takes a LOT of tension.

remember, what you are having to do is to stretch the belt enough for the
encoder to sense movement. After you start it moving it should take almost no
force, but to get it started (especially if the retraction force was high when
it was wound in) can be very hard.

David Lang

13

Um… That’s what I thought. As an engineer, that makes me kinda worried. Especially since our figure of merit for the belts is “low stretch”.

I think a small specified extension at the start of “extend belts” would take this whole issue off the table… Kind of like the “release tension” button.

14

Rod wrote:

I think a small specified extension at the start of “extend belts” would take
this whole issue off the table… Kind of like the “release tension” button.

the problem is is that if there it too much tension released, the belts can
tangle.

but I agree with you that moving a few mm worth would help a lot.

David Lang

15

Progress here!

A straight pull on my machine takes OVER 35 pounds (using a tension meter). I ran out of ability to hold the meter and the Maslow…

About 15 pounds of side pull; leverage on the belt end runs that up about 45 pounds of belt pull, which lines up with my straight pull measurement.

On the good side, all of that gave me the confidence to, um, just yard on that sucker…

Calibration really dragged on; I had to give up and edit the YAML file.

So, a newbie challenge: there’s no way to STOP a function and there isn’t any checking on requirements for “calibrate”.

I mistakenly hit “calibrate” before tensioning the belts, which leaves the Maslow stuck, somehow… Greyed out buttons, no response to any action.

It feels like the Calibrate button should check the state of the machine and throw an error if you are not in the right state…

I’m pretty confident that with the right pre-filled values that I can get to calibration tonight!
*** Can someone confirm that the Maslow_tlZ (and similar) should be the stock 100mm minus the height of the anchor?*** So if I make the anchor heights match the belt spools these all go to zero?

Ok, more weirdness: What is the YAML file supposed to look like???

As far as I can understand, I downloaded this file off the unit, edited dimensions, and uploaded, but I got whining about “messed up yaml file”… [yes, I left off the rest of the parameters]

board: Maslow
name: Maslow S3 Board
meta:
Maslow_vertical: false
Maslow_calibration_grid_width_mm_X: 1500.000000
Maslow_calibration_grid_height_mm_Y: 800.000000
Maslow_calibration_grid_size: 7
Maslow_tlX: 0.000000
Maslow_tlY: 2438.4
Maslow_trX: 3663.95
Maslow_trY: 2438.4
Maslow_blX: 0.000000
Maslow_blY: 0.000000
Maslow_brX: 3663.95
Maslow_brY: 0.000000
Maslow_tlZ: 89.000000
Maslow_trZ: 89.000000
Maslow_blZ: 89.000000
Maslow_brZ: 89.000000

BUT, I’ve also got this one that I got from somewhere in my downloads folder…

board: Maslow
name: Maslow S3 Board

Is the maslow on vertical (true) or horizontal (false)

Maslow_vertical: false

Define the distance from the anchor points to the corners of the calibration grid in mm

maslow_calibration_grid_width_mm_X: 1500
maslow_calibration_grid_height_mm_Y: 800

Defines the number of points in the calibration grid. Options are 3,5,7,9

maslow_calibration_grid_size: 7

#####################################################################

Define the frame

By convention we have defined the bottom left to be (0,0) and the bottom right to be (__,0) but any values are valid.

Bottom, top, left, right are defined with relation to the power cord being down looking from the top of the machine.

All values in millimeters!

Top left corner of frame. nominally 0, height

Maslow_tlX: -27.6
Maslow_tlY: 2064.9

Top right corner of frame. nominally width, height.

Maslow_trX: 2924.3
Maslow_trY: 2066.5

Bottom left. Nominally 0,0

Maslow_blX: 0
Maslow_blY: 0

Bottom right. Nominally width,0

Maslow_brX: 2953.2
Maslow_brY: 0

Z axis values

These define the height of the anchor points in relation to each of the arms. You do not need to change these typically

Maslow_tlZ: 100
Maslow_trZ: 56
Maslow_blZ: 34
Maslow_brZ: 78

16

This is to get it started extending or to keep it extending? It absolutely shouldn’t take that much force, something is wrong for sure.

I think that this is important to figure out before going on because it’s going to make other things not work right.

You should be able to calibrate without applying tension. What state does it say the machine is in when you are seeing those greyed out buttons.

17

Bar,

The pull tests are just the “get it started” forces. Once its started it takes almost nothing to keep going.

BTW, two of my spools don’t retract with less than a 900 tension setting. The other two will retract at 600 (IIRC).

When I accidentally hit “calibrate” with the belts fully extended, the unit just sat there. No motion, no information on the status other than the acknowledgement for “calibrate”. Stop, tension, etc. just got the acknowledgement; no actual actions.

I will try to document more when I get back at it!

18

OK, this sounds like things are great. I would play around with the rocking technique, it shouldn’t be too tough. This video is generally outdated, but the part about extending the belts is the same:

Thanks! I would love to fix that issue.

Specifically, what it says here when that happens would be super helpful to know:

image
image1168×916 43 KB

19

Bar wrote:

This is to get it started extending or to keep it extending? It absolutely shouldn’t take that much force, something is wrong for sure.

start it extending. This matches my experience as well (on two different
machines now)

David Lang

1 Like
20

From what i’ve been doing with:
Everything’s better under the C (a quick poke at the frame flex value)
and
What a difference 1/10th of a millimetre makes (how I got retraction to work at force 3/4/500)

I’ve done the retraction / extension dance a lot in a short period of time with different retraction force / machine state. I’ve observed:

  • Technique gets it working, but mainly because it gives you leverage.
  • After the belts have been retracted, you need to stretch the belt / find some slack in the system from somewhere.
    • Fundamentally the retraction pre-tensions the belt with the amount of force it can exert with the retraction force.
    • So you need to apply that much force + the amount of force needed to stretch the belt enough for the sensor to register.
    • At low retraction forces, there can some slack in the way the belt is spooled that makes it easier.
  • A stiff / frictiony / seized spool makes it significantly worse:
    • You have to overcome the spool friction + retraction force pre-tensioning (though the retraction force would have been a bit lower because of the friction)
    • I guess its worse because the retraction from the motor has a mechanical advantage because of the gearing that’s higher than the mechanical advantage when rocking the attachment.
  • Very speculative, but it also felt non-linear - extending from retracting at 600 required very little force, extending after retracting at 1800 felt like it needed loads, more than 3 times the force.
21

I tore down my Maslow and polished out the rotating parts… Significant reduction in torque required!
Details are on the thread about this…
I made tools to follow the curves. The arc shaped bit will work if you don’t have a lathe :wink:
Just hot glue the sanding strip to it. Hot glue is the right way to do the drum too… Not the weird wedge I used.
Calibration would have gone better if I hadn’t swapped a couple dimensions for TR…
After I fixed that it just too most of a forever, but FINISHED!
It can actually drive in a straight line now! Progress!!!