anbodu else getting these errors?? aldo bottom cables go massivly slack. thought i had fixed it by running without an extractor but still having the smae issues.
Home pos set for: Z
[G54:0.000,0.000,0.000]
JogTo: '$J=G91F2500X-0.09Y5.1
’
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.060mm Counter: 1]
[MSG:WARN: Previous error was 15.060mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.093mm Counter: 2]
[MSG:WARN: Previous error was 15.093mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.118mm Counter: 3]
[MSG:WARN: Previous error was 15.118mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.160mm Counter: 4]
[MSG:WARN: Previous error was 15.160mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.210mm Counter: 5]
[MSG:WARN: Previous error was 15.210mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.200mm Counter: 6]
[MSG:WARN: Previous error was 15.200mm]
[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: 1307]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
anbodu else getting these errors?? aldo bottom cables go massivly slack.
thought i had fixed it by running without an extractor but still having the
smae issues.
is this a 4.0 or 4.1 machine?
do the bottom cables go slack before these errors?
These errors can be caused by poor connections of the ethernet cables on the 4.0
machines (hot glue helps), and sometimes by static electricity.
on both versions, they can be caused by the magnet slipping or being in the
wrong place
has a solution been found to stop it? dont really want to be hot gluing in my connectors.
you don’t put the glue in the connection, you use the hot melt glue to hold the
rj-45 in place and keep it from vibrating. (I’ve been using it to keep
electronic/computer connectors from creeping for many years)
the 4.1 version is largely to replace these connectors with ones that are more
reliable and resistant to dust and vibration.
I am as well.
I have gone through several rebuilds of my router to fix miscellaneous issues and now have what seems to be a smooth running 4.1 machine.
The machine calibrated after the second try and subsequent test runs (no power to the router) work with small project pieces.
These are typically pieces centered on the spoil board and are approximately 600 x 600mm.
I am using Fusion and outputting with a GBRL post process.
The problem so far is with larger projects where the pieces extend near the edges of the spoil board. The very first transition (jog) that moves the router to the right results in a position error.
The belts remain tight and the actually move seems smooth just before getting the error. I have tried this with several files, and the result is the same. Below is the excerpt of the log where I had just re-calibrated and tried to run one of the larger jobs.
Calibration values:
Fitness: 0.6384880195065752
Maslow_tlX: -4.7
Maslow_tlY: 2410.1
Maslow_trX: 3091.9
Maslow_trY: 2411.1
Maslow_blX: 0.0
Maslow_blY: 0.0
Maslow_brX: 3105.4
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 Ready To Cut to Calibrating]
[MSG:INFO: Setting z-stop position]
[MSG:INFO: Machine Position found as X: -0.021 Y: -5.043]
[MSG:INFO: Succeeded]
[MSG:INFO: Requesting state change from Calibrating to Ready To Cut]
[MSG:INFO: Succeeded]
JogTo: '$J=G91F2500X0.03Y5.04
’
[MSG:INFO: Tool No: 1]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.006mm Counter: 1]
[MSG:WARN: Previous error was 15.006mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.032mm Counter: 2]
[MSG:WARN: Previous error was 15.032mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.052mm Counter: 3]
[MSG:WARN: Previous error was 15.052mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.077mm Counter: 4]
[MSG:WARN: Previous error was 15.077mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.110mm Counter: 5]
[MSG:WARN: Previous error was 15.110mm]
[MSG:WARN: Position error on Top Right axis exceeded 15mm while running. Error is 15.143mm Counter: 6]
[MSG:WARN: Previous error was 15.143mm]
[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: 28]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
It’s possible that we’re just telling the machine to move faster than it is physically able to do since the max movement speed is dependent on the frame size.
Can you try turning down how fast the machine moves while jogging and see if that fixes the issue?
Turned the XY feed rate down to 2000 mm/min and tried to run one of the projects (router off).
Getting similar result but the sled did actually jog to the start point and start ramping down where previously it had stopped just before the actual cut.
I am getting a motor warning just before the error though, this warning occurs almost every time.
There is no slack in the BL belt when the emergency stop occurs
The stop occurs at ~1000mm on the X axis.
What I find curious is that I can jog the sled manually past this point and back to home with no issues.
Below is the serial output:
Index.html Version: 1.06
[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:SemperFi]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting..]
[MSG:INFO: Connected - IP is 192.168.1.45]
[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]
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 -1212.222]
[MSG:INFO: Top Right pulled tight with offset -1196.869]
[MSG:INFO: Top Left pulled tight with offset -2672.082]
[MSG:INFO: Bottom Left pulled tight with offset -2666.607]
[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 1850.000mm]
[MSG:INFO: Requesting state change from Extending Belts to Belts Extended]
[MSG:INFO: Succeeded]
Apply Tension
[MSG:INFO: Requesting state change from Belts Extended to Taking Slack]
[MSG:INFO: Succeeded]
Maslow is not ready to move.
[MSG:INFO: Measured waypoint 2]
[MSG:INFO: Center point deviation: TL: 0.000 TR: 0.000 BL: -0.417 BR: 1.243]
[MSG:INFO: Center point deviation within 12.000mm, your coordinate system is accurate]
[MSG:INFO: Current machine position loaded as X: -4.877 Y: -65.714]
[MSG:INFO: Requesting state change from Taking Slack to Ready To Cut]
[MSG:INFO: Succeeded]
JogTo: '$J=G91F2000X4.88Y65.71 (move to home)
’
[MSG:INFO: Tool No: 1] (start of job)
[MSG:WARN: Motor current on Bottom Left axis exceeded threshold of 4000]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.015mm Counter: 1]
[MSG:WARN: Previous error was 15.015mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.037mm Counter: 2]
[MSG:WARN: Previous error was 15.037mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.057mm Counter: 3]
[MSG:WARN: Previous error was 15.057mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.083mm Counter: 4]
[MSG:WARN: Previous error was 15.083mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.103mm Counter: 5]
[MSG:WARN: Previous error was 15.103mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.129mm Counter: 6]
[MSG:WARN: Previous error was 15.129mm]
[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: 25]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
Turned the XY feed rate down to 2000 mm/min and tried to run one of the projects (router off).
Getting similar result but the sled did actually jog to the start point and start ramping down where previously it had stopped just before the actual cut.
I am getting a motor warning just before the error though, this warning occurs almost every time.
There is no slack in the BL belt when the emergency stop occurs
that motor current warning is saying that it’s applying as much power to the
motor as it can, if it then throws the position error, that means that full
power isn’t good enough to keep up.
you can try slowing down more, or you can dig into that arm and see if there is
a problem causing more friction than you should have,
Is this a 4.0 machine or a 4.1 machine? with the 4.0 arms it was possible to
position the motors too close to the idler so it takes an excessive amount of
force to run (what current limit do you need to set to reliably retract?)
Appreciate the feedback.
The machine is a 4.1 and retraction force is currently set at 1400 because once in a while the bottom right would not retract at 900 so I just set it at the higher current value and have not experienced any retract issues since.
It seems a reasonable conclusion that the BL arm is having an issue, but subsequent tests where I start the cut at center and traverse to the left result in the same 15mm position error and subsequent e-stop (albeit without the current warning).
I started looking at the G code and noticed a G0 (Rapid positioning) so I modified the Fusion parameters to a max 2000mm/min rapid feed rate thinking it might be the problem, but it has not helped. The error only seems to occur near the ends of the panel X < -1000 X >1000 on the panel which makes me think it is related to calibration.
Last test run:
Index.html Version: 1.06
[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:SemperFi]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting..]
[MSG:INFO: Connected - IP is 192.168.1.45]
[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]
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 -1185.865]
[MSG:INFO: Top Right pulled tight with offset -1221.455]
[MSG:INFO: Top Left pulled tight with offset -2726.085]
[MSG:INFO: Bottom Left pulled tight with offset -2723.154]
[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 1850.000mm]
[MSG:INFO: Requesting state change from Extending Belts to Belts Extended]
[MSG:INFO: Succeeded]
Apply Tension
[MSG:INFO: Requesting state change from Belts Extended to Taking Slack]
[MSG:INFO: Succeeded]
[MSG:INFO: Measured waypoint 2]
[MSG:INFO: Center point deviation: TL: 0.000 TR: 0.000 BL: 0.053 BR: 0.342]
[MSG:INFO: Center point deviation within 12.000mm, your coordinate system is accurate]
[MSG:INFO: Current machine position loaded as X: -5.059 Y: -65.716]
[MSG:INFO: Requesting state change from Taking Slack to Ready To Cut]
[MSG:INFO: Succeeded]
JogTo: '$J=G91F2000X5.06Y65.71
’
[MSG:INFO: Tool No: 1]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.006mm Counter: 1]
[MSG:WARN: Previous error was 15.006mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.002mm Counter: 1]
[MSG:WARN: Previous error was 15.002mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.029mm Counter: 2]
[MSG:WARN: Previous error was 15.029mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.049mm Counter: 3]
[MSG:WARN: Previous error was 15.049mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.083mm Counter: 4]
[MSG:WARN: Previous error was 15.083mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.031mm Counter: 5]
[MSG:WARN: Previous error was 15.031mm]
[MSG:WARN: Position error on Top Left axis exceeded 15mm while running. Error is 15.065mm Counter: 6]
[MSG:WARN: Previous error was 15.065mm]
[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: 28]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]
Does anyone know what/why there is a “Measured waypoint 2” message in the output?
Apply Tension
[MSG:INFO: Requesting state change from Belts Extended to Taking Slack]
[MSG:INFO: Succeeded] [MSG:INFO: Measured waypoint 2]
[MSG:INFO: Center point deviation: TL: 0.000 TR: 0.000 BL: 0.053 BR: 0.342]
[MSG:INFO: Center point deviation within 12.000mm, your coordinate system is accurate]
[MSG:INFO: Current machine position loaded as X: -5.059 Y: -65.716]
[MSG:INFO: Requesting state change from Taking Slack to Ready To Cut]
[MSG:INFO: Succeeded]
Moved the sled to start point of the first cut and ran the job but still got the position error at approximately X pos -1045.
I am on a vertical setup and cutting parts out of a 2500x1220x12mm panel. The parts are all at least 47mm from the panel edge. The parts are frames for a 28-foot boat which is why I need to utilize as much of the plywood panel as possible.
In this particular test (no cutting) the error is thrown on the very first instruction that starts the ramp cut:
G1 Z2.5 F600
S8000 (speed instruction is a hold-over from setup on my AVID CNC and has no effect)
X-0.001 Z-5 F1500
S12500 (speed instruction is a hold-over from setup on my AVID CNC and has no effect)
X-1167.19
Am I pushing the limit here?
The machine runs quite smoothly and as stated previously, I can manually jog the sled to the edge of the parts with no issues and can run smaller jobs also with no problems. The problem does appear to be related to driving the sled close to the edges.
Its a hardware issue where the machine can’t do what is being asked of it either because it can’t move that fast or it can’t move to the target location because maybe the tension in the belts is too high?
It’s a software issue and there is something about that gcode file which the machine isn’t happy about.
If it’s not too secret would you be willing to post your gcode file and I’ll try running it on my machine and see if I can replicate the behavior that you are seeing?
All the issues I encountered was due to the spools binding on the arms.
I am confident that the spool to arm fit got worse as time went by due to environmental conditions.
The initial fit of the spools to the arms felt snug but I could rotate the spool on both halves of the arms smoothly. Subsequent disassembly showed they were very tight and binding.
Increasing the clearance between the spools and arms (sanding and polishing the spools inside circumference) resulted in both better calibration and eventual success in running jobs.
I am sure the extreme conditions here in Florida coupled with the fact that I am running my machine outside (under cover) resulted in the plastic expanding.
Some of the signs this was occurring include the following:
Stress marks on the spool teeth.
Low fitness values when calibrating
Position errors when the sled moved to the outer areas of the panel
A well-defined ridge on the inside of the spools when inspected after disassembly
Difficulty spinning the spool on the arm halves when fitting.
None of these issues were present after initial assembly.
Not aware of what kind of plastic is being used but I am aware that both nylon and polycarbonates absorb moisture and that seems to be what is occurring. A looser slip fit between the spools and arm halves would help alleviate this problem.
