Recurring Issue, loose belts and maslow stops and disconnects

Troubleshooting
1

I’m trying to run a program to cut out some boxes. I am seeing a couple of possible issues.

  1. 1 or 2 of the belts get loose (not touching the wood, but loose) when jogging
  2. Maslow has disconnected randomly several times today and i get an error about a corrupt maslow.yaml and told to reboot. I’ve tried that reboot a few times and then try to re-run the program. I get to the same spot each time and maslow stops moving and disconnects. below is the serial log. Any ideas what’s going on? I’ve tried firmware v.84 and tried to downgrade to 82.2 but i have the same issue. It’s also odd because I was able to cut for about 2 hours today before running into this issue, but i’ve now reset and tried a few different programs but i get the same error. Cuts have also been a bit off (i’m assuming because of the loose belts). Sorry if i’m rambling, it’s been a few hours of messing with this thing and looks like i’ll finish the weekend with nothing but a bit of sawdust and wasted time to show for it :frowning:
    Any help would be appreciated.

Serial Messages
Index.html Version: 0.81
[MSG:INFO: Channel auto report interval set to 50 ms]
[MSG:INFO: FluidNC v0.81 (Maslow-Main-40fc4740-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:Aggienetwork]
[MSG:INFO: Connecting.]
[MSG:INFO: Connecting…]
[MSG:INFO: Connected - IP is 10.79.1.239]
[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: Caution: Unlocked]
[MSG:INFO: Retracting all belts]
[MSG:INFO: Bottom Left pulled tight with offset -0.021]
[MSG:INFO: Top Right pulled tight with offset -0.054]
[MSG:INFO: Top Left pulled tight with offset -0.064]
[MSG:INFO: Bottom Right pulled tight with offset -0.064]
[MSG:INFO: Extending all belts]
[MSG:INFO: All belts extended to center position]
Jog: Z5
Jog: Z5
[MSG:INFO: Measured waypoint 0]
[MSG:INFO: Center point deviation: TL: 0.202 TR: 0.016 BL: 6.045 BR: 6.758]
[MSG:INFO: Center point deviation: TL: 0.202 TR: 0.016 BL: 6.045 BR: 6.758]
[MSG:INFO: Center point deviation within 15.000mm, your coordinate system is accurate]
Jog: Z5
[MSG:INFO: Measured waypoint 0]
[MSG:INFO: Center point deviation: TL: 0.178 TR: 0.021 BL: 6.408 BR: 7.596]
[MSG:INFO: Center point deviation: TL: 0.178 TR: 0.021 BL: 6.408 BR: 7.596]
[MSG:INFO: Center point deviation within 15.000mm, your coordinate system is accurate]
error:8 - Command requires idle state. Unlock machine?
Jog: Z-5
Jog: Z-1
Jog: Z1
Home pos set for: Z
error:9
Home pos set for: Z
[G54:225.000,-250.000,96.650]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.026mm Counter: 1]
[MSG:WARN: Previous error was 15.026mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.048mm Counter: 2]
[MSG:WARN: Previous error was 15.048mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.055mm Counter: 3]
[MSG:WARN: Previous error was 15.055mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.077mm Counter: 4]
[MSG:WARN: Previous error was 15.077mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.106mm Counter: 5]
[MSG:WARN: Previous error was 15.106mm]
[MSG:WARN: Position error on Bottom Left axis exceeded 15mm while running. Error is 15.128mm Counter: 6]
[MSG:WARN: Previous error was 15.128mm]
[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: 40]
[MSG:ERR: Position error > 15mm while running. E-Stop triggered.]

2 Likes
2

That’s probably a 152 error “Configuration is invalid. Maslow.yaml file may be corrupt. Turning off and back on again can often fix this issue.”

The maslow.yaml may be corrupt, although that’s not always the case. However, the working configuration state of the M4 is definitely corrupt.

The most common reason for this is that the ESP32 (the CPU of the M4) has thrown an ESP_RST_PANIC error (effectively lost its mind) and it has fallen back to the ‘default’ config which is not enough to actually use the machine, just enough to make sure it doesn’t do something really bad.

If this is occurring a lot then something is wrong e.g. with the M4, or with your environment - lots of EMF.

3

thanks for the response. I thought maybe it was static, i tried twice without the vacuum hooked up or on, but still got the same issue.

4

I used to get the ESP_RST_PANIC error, which is why i fixed the code so the ‘default’ config wouldn’t do something horrible to the machine.

However, I was never able to conclusively identify the source of the problem. Except that it may have been software related more than something else.

So I’d definitely recommend making sure that all of your software, in this case especially the firmware, is fully up to date

5

I had just updated to the latest firmware (0.84, I think) yesterday.

Other question I have is would this error be responsible for the belts being loose? I have a video, I’ll see if I can upload it. I assume that is what’s causing some of the cuts to be off.

Video: https://youtube.com/shorts/XDEjcXfQykY?si=fCxnCi8NWk6JTcC4

6

I had this same issue, here’s the thread with my notes and a video. Replacing the maslow.yaml file with a fresh one did the trick for me. Belts become loose on any axis movement - #28 by kyleschoen

2 Likes
7

Thank you. I’ll give that a try this week and see if that resolves the issue.

1 Like
8

This issue is commonly caused by dust in the ethernet ports. We’re working on a more permanent fix, but right now cleaning them out with compressed air or computer duster and using hot glue to hold the connectors in place seems to help a lot.

1 Like
9

Are you using a vertical or horizontal setup? I had the same issue when running vertical. Haven’t seen it since running on the garage floor. Prior to hot glueing the connectors I would see a similar error that also mentioned an encoder problem.

1 Like
10

I’m running horizontally. built a frame on the garage floor that i’ll eventually mount on a wall with a hinge to raise it out of the way, but for now it’s just flat on the floor.

1 Like
11

My horizontal setup is drilled into the floor. Had a theory that my wooden vertical frame was flexing…

When I got the 15 mm error, it would fail again soon. If I waited overnight it would run again the next morning.

12

Nate wrote:

When I got the 15 mm error, it would fail again soon. If I waited overnight it would run again the next morning.

The 15mm error is almost always a problem with the encoders or the cables to
them. hot glue on the cable ends and/or grounding the pin on the encoders seems
to be the fix (until the new boards are tested and out)

David Lang

1 Like
13

The hot glue resolved the encoder error followed by the 15 mm error. However, it did not resolve the 15 mm error on its own. I suspect there are multiple sources of the 15mm error.

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14

Upgraded the firmware and replaced maslow.yaml and tried again this afternoon. I also blew out the Ethernet ports (didn’t see any dust in there at all, but did it anyway) and…

Belts still loose. Then one started to unspool while cutting so I had to mash the e-stop. I guess I need to try doing calibration again? Or what’s the next step?

15

Wes wrote:

Upgraded the firmware and replaced maslow.yaml and tried again this afternoon. I also blew out the Ethernet ports (didn’t see any dust in there at all, but did it anyway) and…

Belts still loose. Then one started to unspool while cutting so I had to mash the e-stop. I guess I need to try doing calibration again? Or what’s the next step?

Yes, the calibration sets the Maslow_* variables in the .yaml file, if you
replace it, you either need to do calibration again, or copy the values of those
variables over (and if you are replacing it because you are having problems with
belt tension, you don’t want to copy them over, you want to do a new
calibration)

but after you finish the calibration, note the anchor point locations, either
from the final report from the calibration (also copy the fitness score) or from
the maslow.yaml file

@bar can we have it store the fitness from the calibration into the .yaml as
well? just so we can look later and know what the fitness was that generated
that calibration.

David Lang

16

I did copy the values over, but I’ll try to run calibration again tomorrow and see what happens.

1 Like
17

Updated to 0.84.1, including replacing maslow.yaml again and started calibration. I made it through one iteration and then got disconnected and calibration stopped. When I reconnected, I got a message about maslow.yaml being corrupt.

I have family over this afternoon so i haven’t been able to try again.

18

Updated to the new JST-xh encoders and did a recalibration and run. Program got about 2/3 of the way through and then stopped. The error message didn’t tell me much, but I will post it here when I get back on the computer. The bottom left belt seems to be stuck, so I’m guessing that is what caused the program to stop running. I haven’t figured out why the belt got stuck yet, I’ll have to look into that tomorrow.

Overall things went much better, until they didn’t…

1 Like