Hi all,
I’m running into an issue with my Maslow 4.0 during cuts. The lower right belt keeps loosening and ends up unwinding inside the belt spool.This happens partway through the job. I’ve already done a successful cut on the left side of the frame. This is the first time doing a cut in the right side of the frame.
Has anyone experienced something similar? I’m trying to understand what could be causing this and how could I try and fix it.
Version: 1.06
Can you get a video of it happening?
The first things that come to mind are that it could be a calibration issue (running calibration again might fix it) or it could be a lose magnet in one of the rollers.
Does it happen exactly the same every time?
If you move the machine back to the left side of the frame does the belt tighten up or stay lose?
I have the same issue however with the lower left belt while working on the left side.
I’ve been cutting in the middle with no issues, only did a 800x800 5x5 calibration.
I’ll run a new more ambitious calibration and report back.
I’m on 1.07
I ran another test before calibration as I would have to remove the stock to calibrate.
The same thing happened and the cut failed the same way.
It was the second time so no stock was removed. I took some videos and can add the serial output
The videos in a Dropbox folder:https://www.dropbox.com/scl/fo/4nqciga1lmbpaqcnl8rk5/AF5CQpflxpItjBfoG11AGFA?rlkey=s1oxs0f74kskr5rdgff1dutrm&st=g91cn4dc&dl=0
I did a new calibration with calibration force 1200, 1200x800 and 7x7 grid.
The issue with slack belts is resolved.
So the final solution was to run the calibration process but with more force?
Yes.
When I used less force the calibration did not converge, could there be a problem with friction in the arms?
I just upgraded my 4 to 4.1.
Maybe, but also it’s fine to just have things set to a higher tension. 1200 used to be the default setting so that’s not crazy high or anything.
Bar, JitM, thanks for taking the time.
I successfully ran the calibration with calibration force 1200, 1200x800 and 7x7 grid. I was able to make a successful cut, before getting the position error: “Position error on Top Right axis exceeded 15mm while running”.
Today I try to repeat the calibration with these settings but the calibration didnt converged. I tried with the default calibration 500x500 and 900 force, and it succeeded. Nevertheless, I tried to cut a piece, but the position error showed up again.
I’m running out of ideas.
See log below, if it helps:
Serial Messages
Index.html Version: 1.07
[MSG:INFO: Channel auto report interval set to 50 ms]
[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: Connecting to STA SSID:dell]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting..]
[MSG:INFO: Connected - IP is 192.168.137.164]
[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]
[MSG:INFO: Channel auto report interval set to 50 ms]
Release Tension
[MSG:INFO: Requesting state change from Unknown to Releasing Tension]
[MSG:INFO: Succeeded]
[MSG:INFO: Requesting state change from Releasing Tension to Unknown]
[MSG:INFO: Succeeded]
Release Tension
[MSG:INFO: Requesting state change from Unknown to Releasing Tension]
[MSG:INFO: Succeeded]
[MSG:INFO: Requesting state change from Releasing Tension to Unknown]
[MSG:INFO: Succeeded]
[MSG:WARN: Bad connection on Top Right encoder, failed to read 1 times in the last second]
[MSG:ERR: Emergency stop. Update function not being called enough.1001ms since last call]
Retract All
[MSG:INFO: Retracting all belts]
[MSG:INFO: Requesting state change from Unknown to Retracting Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: Bottom Left pulled tight with offset -1586.385]
[MSG:INFO: Top Left pulled tight with offset -1601.351]
[MSG:INFO: Bottom Right pulled tight with offset -1813.679]
[MSG:INFO: Top Right pulled tight with offset -1839.649]
[MSG:INFO: Requesting state change from Retracting Belts to Belts Retracted]
[MSG:INFO: Succeeded]
Extend All
[MSG:INFO: Extending all belts]
[MSG:INFO: Requesting state change from Belts Retracted to Extending Belts]
[MSG:INFO: Succeeded]
[MSG:INFO: All belts extended to 1720.000mm]
[MSG:INFO: Requesting state change from Extending Belts to Belts Extended]
[MSG:INFO: Succeeded]
Calibrate
[MSG:INFO: Requesting state change from Belts Extended to Calibrating]
[MSG:INFO: Setting z-stop position]
[MSG:INFO: Machine Position found as X: -3.589 Y: -48.514]
[MSG:INFO: Succeeded]
[MSG:INFO: Measured waypoint 0]
[MSG:INFO: Center point off by: TL: 0.000 TR: 0.000 BL: 5.567 BR: 4.317]
[MSG:INFO: Machine Position computed as X: -3.401 Y: -30.189]
[MSG:INFO: Measuring Frame Flex]
[MSG:ERR: Measurement error, measurements are not within 2.5 mm of each other, trying again]
[MSG:INFO: Max deviation: 4.037]
[MSG:INFO: Bottom Right 1871.035]
[MSG:INFO: Bottom Right 1871.046]
[MSG:INFO: Bottom Right 1871.089]
[MSG:INFO: Bottom Right 1871.089]
[MSG:INFO: Top Right 1872.914]
[MSG:INFO: Top Right 1872.914]
[MSG:INFO: Top Right 1873.032]
[MSG:INFO: Top Right 1873.107]
[MSG:INFO: Top Left 1860.421]
[MSG:INFO: Top Left 1860.421]
[MSG:INFO: Top Left 1856.383]
[MSG:INFO: Top Left 1856.351]
[MSG:INFO: Bottom Left 1839.900]
[MSG:INFO: Bottom Left 1839.911]
[MSG:INFO: Bottom Left 1839.922]
[MSG:INFO: Bottom Left 1839.911]
[MSG:INFO: Flex measurement: TLBR: 2.171 TRBL: 3.852]
[MSG:INFO: Measured waypoint 1]
[MSG:INFO: Measured waypoint 2]
[MSG:INFO: Measured waypoint 3]
[MSG:INFO: Measured waypoint 4]
[MSG:INFO: Measured waypoint 5]
[MSG:INFO: Requesting state change from Calibrating to Calibration Computing]
[MSG:INFO: Succeeded]
CLBM:[{bl:1860.42, br:1842.31, tr:1872.87, tl:1870.88},{bl:1979.30, br:1727.53, tr:1759.09, tl:1988.14},{bl:2064.47, br:1818.07, tr:1666.28, tl:1913.20},{bl:1951.45, br:1930.80, tr:1783.01, tl:1788.05},{bl:1836.47, br:2047.41, tr:1910.46, tl:1665.15},{bl:1740.67, br:1965.98, tr:1992.32, tl:1751.31},]
Computing… This may take several minutesFitness: 0.1519213 in 100
Fitness: 0.2124598 in 200
Fitness: 0.2449519 in 300
Fitness: 0.2610459 in 400
Fitness: 0.3422268 in 500
Fitness: 0.5618403 in 600
Fitness: 0.9521849 in 700
Fitness: 1.2623125 in 800
Fitness: 1.3555364 in 900
Fitness: 1.3555364 in 1000
Fitness: 1.3555364 in 1100
Fitness: 1.3555364 in 1200
Fitness: 1.3555364 in 1300
Fitness: 1.3555364 in 1400
Fitness: 1.3555364 in 1500
Fitness: 1.3555364 in 1600
Fitness: 1.3555364 in 1700
Fitness: 1.3555364 in 1800
Calibration values:
Fitness: 1.3555362948909566
Maslow_tlX: 28.2
Maslow_tlY: 2018.3
Maslow_trX: 3133.9
Maslow_trY: 2024.5
Maslow_blX: 0.0
Maslow_blY: 0.0
Maslow_brX: 3144.6
Maslow_brY: 0.0
A command to save these values has been successfully sent for you. Please check for any error messages.
Calibrate
[MSG:INFO: Requesting state change from Calibration Computing to Calibrating]
[MSG:INFO: Setting z-stop position]
[MSG:INFO: Machine Position found as X: -136.390 Y: -37.975]
[MSG:INFO: Succeeded]
[MSG:INFO: Measured waypoint 6]
[MSG:INFO: Measured waypoint 7]
[MSG:INFO: Measured waypoint 8]
[MSG:INFO: Measured waypoint 9]
[MSG:INFO: Measured waypoint 10]
[MSG:INFO: Measured waypoint 11]
[MSG:INFO: Measured waypoint 12]
[MSG:INFO: Measured waypoint 13]
[MSG:INFO: Measured waypoint 14]
[MSG:INFO: Requesting state change from Calibrating to Calibration Computing]
[MSG:INFO: Succeeded]
CLBM:[{bl:1860.42, br:1842.31, tr:1872.87, tl:1870.88},{bl:1979.30, br:1727.53, tr:1759.09, tl:1988.14},{bl:2064.47, br:1818.07, tr:1666.28, tl:1913.20},{bl:1951.45, br:1930.80, tr:1783.01, tl:1788.05},{bl:1836.47, br:2047.41, tr:1910.46, tl:1665.15},{bl:1740.67, br:1965.98, tr:1992.32, tl:1751.31},{bl:1869.22, br:1873.95, tr:1861.83, tl:1838.77},{bl:1747.23, br:1741.38, tr:2000.36, tl:1986.05},{bl:1531.18, br:1965.31, tr:2199.63, tl:1805.35},{bl:1669.50, br:2084.03, tr:2073.82, tl:1641.13},{bl:1829.58, br:2212.48, tr:1963.85, tl:1500.83},{bl:2011.44, br:2014.40, tr:1738.53, tl:1714.74},{bl:2215.85, br:1832.97, tr:1517.44, tl:1942.47},{bl:2091.48, br:1670.40, tr:1649.64, tl:2054.32},{bl:1974.64, br:1529.08, tr:1812.29, tl:2186.27},]
Computing… This may take several minutesFitness: 0.5919824 in 100
Fitness: 0.5920835 in 200
Fitness: 0.5920835 in 300
Fitness: 0.5920835 in 400
Fitness: 0.5920835 in 500
Fitness: 0.5920835 in 600
Fitness: 0.5920835 in 700
Fitness: 0.5920835 in 800
Fitness: 0.5920835 in 900
Fitness: 0.5920835 in 1000
Fitness: 0.5920835 in 1100
Calibration values:
Fitness: 0.5920834885085475
Maslow_tlX: 21.8
Maslow_tlY: 2018.3
Maslow_trX: 3132.6
Maslow_trY: 2024.5
Maslow_blX: 0.0
Maslow_blY: 0.0
Maslow_brX: 3136.4
Maslow_brY: 0.0
A command to save these values has been successfully sent for you. Please check for any error messages.
Calibrate
[MSG:INFO: Requesting state change from Calibration Computing to Calibrating]
[MSG:INFO: Setting z-stop position]
[MSG:INFO: Machine Position found as X: 249.707 Y: -240.012]
[MSG:INFO: Succeeded]
[MSG:INFO: Measured waypoint 15]
[MSG:INFO: Measured waypoint 16]
[MSG:INFO: Requesting state change from Calibrating to Calibration Computing]
[MSG:INFO: Succeeded]
CLBM:[{bl:1860.42, br:1842.31, tr:1872.87, tl:1870.88},{bl:1979.30, br:1727.53, tr:1759.09, tl:1988.14},{bl:2064.47, br:1818.07, tr:1666.28, tl:1913.20},{bl:1951.45, br:1930.80, tr:1783.01, tl:1788.05},{bl:1836.47, br:2047.41, tr:1910.46, tl:1665.15},{bl:1740.67, br:1965.98, tr:1992.32, tl:1751.31},{bl:1869.22, br:1873.95, tr:1861.83, tl:1838.77},{bl:1747.23, br:1741.38, tr:2000.36, tl:1986.05},{bl:1531.18, br:1965.31, tr:2199.63, tl:1805.35},{bl:1669.50, br:2084.03, tr:2073.82, tl:1641.13},{bl:1829.58, br:2212.48, tr:1963.85, tl:1500.83},{bl:2011.44, br:2014.40, tr:1738.53, tl:1714.74},{bl:2215.85, br:1832.97, tr:1517.44, tl:1942.47},{bl:2091.48, br:1670.40, tr:1649.64, tl:2054.32},{bl:1974.64, br:1529.08, tr:1812.29, tl:2186.27},{bl:1745.33, br:1730.75, tr:2002.91, tl:1996.27},{bl:1867.97, br:1864.10, tr:1862.96, tl:1848.12},]
Computing… This may take several minutesFitness: 0.5279866 in 100
Fitness: 0.5279866 in 200
Fitness: 0.5279866 in 300
Fitness: 0.5279866 in 400
Fitness: 0.5279866 in 500
Fitness: 0.5279866 in 600
Fitness: 0.5279866 in 700
Fitness: 0.5279866 in 800
Fitness: 0.5279866 in 900
Fitness: 0.5279866 in 1000
Calibration values:
Fitness: 0.5279865612636535
Maslow_tlX: 21.8
Maslow_tlY: 2018.3
Maslow_trX: 3132.6
Maslow_trY: 2024.5
Maslow_blX: 0.0
Maslow_blY: 0.0
Maslow_brX: 3136.0
Maslow_brY: 0.0
A command to save these values has been successfully sent for you. Please check for any error messages.
Calibrate
[MSG:INFO: Requesting state change from Calibration Computing to Calibrating]
[MSG:INFO: Setting z-stop position]
[MSG:INFO: Machine Position found as X: 0.164 Y: -5.241]
[MSG:INFO: Succeeded]
[MSG:INFO: Requesting state change from Calibrating to Ready To Cut]
[MSG:INFO: Succeeded]
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500X50
’
JogTo: '$J=G91F2500Y100
’
JogTo: '$J=G91F2500Y100
’
JogTo: '$J=G91F2500Y100
’
JogTo: '$J=G91F2500Y100
’
JogTo: '$J=G91F2500Y50
’
JogTo: '$J=G91F2500Y-250
’
JogTo: '$J=G91F2500Y-250
’
JogTo: '$J=G91F2500Y-250
’
JogTo: '$J=G91F2500Y-100
’
JogTo: '$J=G91F2500Y-100
’
JogTo: '$J=G91F2500Y-50
’
JogTo: '$J=G91F2500Y-50
’
JogTo: '$J=G91F2500Y-50
’
Home pos set for: X
Home pos set for: Y
[G54:300.163,-600.150,30.400]
[G54:300.163,-655.237,30.400]
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z5
’
JogTo: '$J=G91F300Z-5
’
JogTo: '$J=G91F300Z-15
’
JogTo: '$J=G91F300Z-5
’
JogTo: '$J=G91F300Z-5
’
JogTo: '$J=G91F300Z-2
’
JogTo: '$J=G91F300Z-2
’
JogTo: '$J=G91F300Z-1
’
JogTo: '$J=G91F300Z-1
’
Home pos set for: Z
[G54:300.163,-655.237,34.000]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.029mm Counter: 1]
[MSG:WARN: Previous error was 15.029mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.044mm Counter: 2]
[MSG:WARN: Previous error was 15.044mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.050mm Counter: 3]
[MSG:WARN: Previous error was 15.050mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.088mm Counter: 4]
[MSG:WARN: Previous error was 15.088mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.126mm Counter: 5]
[MSG:WARN: Previous error was 15.126mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.164mm Counter: 6]
[MSG:WARN: Previous error was 15.164mm]
[MSG:ERR: Emergency stop! Stopping all motors]
[MSG:WARN: The machine will not respond until turned off and back on again]
[MSG:INFO: Reset during file job at line: 32]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
Pasting the serial log, I noticed the initial warning at the very top:
[MSG:WARN: Bad connection on Top Right encoder, failed to read 1 times in the last second]
Im gonna check that encoder to see if I can find something off.
When, during the cut did you get the position error, was it when the machine was moving diagonally to another position? If so would you be willing to post a copy of your gcode?
Hi,
I disassembled/assembled the top right arm and didn’t find anything that strike me as outplace.
During testing, I observed that the Maslow’s motion varies across the frame:
Please find attach a couple of small videos of the maslow moving. One is the maslow moving on the mid portion of the frame, and the other is on the right side.
What could be causing this behavior?
Thanks,
Jose
Ps: I have also attached the gcode you asked.
cup holder vertical v2.nc (85.0 KB)
I didn’t see anything in the video which jumped out to me as being particularly out of the ordinary.
How tight are the belts. Does it feel like they are too tight in the areas where it isn’t moving the way you would like it to?
So, today I extacted all the belts lenghts and retract them with 900 force, no issues. Then I recalibrated the maslow using 1200x800 and 7x7 grid with calibration force of 1400.
I moved around the maslow, but the smooth zone more or less remainning the same as previously pictured. So, I decided to make a cut of something that fitted inside the middle zone.
70% thru the cut, an error message appear and it stop cutting. See the log attached:
[MSG:WARN: Motor current on Top Right axis exceeded threshold of 4000]
[MSG:WARN: Motor current on Top Left axis exceeded threshold of 4000]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.017mm Counter: 1]
[MSG:WARN: Previous error was 15.017mm]
Maslow-serial(3).log (9.8 KB)
The upper belts seem really tight, which would coincide with the 4000 threshold motor current. What could be the cause for this?
Maybe the mismatch here between 900 and 1400 could be creating too much tension in the belts?
The higher the retraction force when calibrating the more tight the belts will be while cutting
I made the design bit smaller too fit in the middle zone, and was able to successfully cut 3 of this pieces with good repeatability.
Regarding the calibration force, I increased it base on the suggestion by JitM. I see the machine moving better with higher calibration forces. Maybe this is a lead on what could be wrong in my setup?
In my case, the 15mm error was fixed with hot glue on the JST connectors, and I fixed the 4000 alert by smoothing out the spools.
Hot glue is a pain, especially when disassembling the machine, so this was definitely fixed with the 4.1 update.
