C- Axis (Tool lock) problems

Discussion in 'Tool heads & ToolChanger' started by MIKE_S0, Jan 9, 2022.

  1. MIKE_S0

    MIKE_S0 Member

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    I have printed already a few test prints and the tool changing is working. But every now and then (yesterday I was running a 10h print but after 9h, the T1 tool fell down) he pulls the tool back after drop off (mostly T0 and T1).
    I found an issue with the grub screw in the tool head and replaced the grub screw. I also made some makings to monitor the angle for the rotation.

    After doing that, the TC lost again T1. The Pinter still proceed with the work, but the Y position was off. Most likely, he hit the tool when he tried to pick it up the next time. The C-Axis was also not straight anymore (well, the markings for horizontal did not add up anymore). After recalibration of the printer, everything looks fine, and he is printing and changing tools normal.

    I use 4 hemera tools and RepRapFirmware for Duet 2 WiFi/Ethernet 3.3
    I attached the config file and the tfreeX.g (I made the return after the drop-off slower)

    I will start recording the movements, specially the rotation of the C-axis. But maybe you guys have an idea what it could be ?

    Code:
    ; Configuration file for Duet WiFi / Ethernet running RRF3 on E3D Tool Changer
    ; executed by the firmware on start-up
    
    ; General preferences
    M111 S0                         ; Debugging off
    G21                             ; Work in millimetres
    G90                             ; Send absolute coordinates...
    M83                             ; ...but relative extruder moves
    M555 P2                         ; Set firmware compatibility to look like Marlin
    M669 K1                         ; Select CoreXY mode    ;M667 S1 --- 2021.12.06 MISOM --- rrf 3.x comand has changed
    
    ; Network
    M550 P"ToolChanger"             ; Set machine name
    ;M587 S"ssid" P"password"        ; WiFi Settings
    ;M552 S1 P"ssid"                ; Enable WiFi Networking
    M552 S1                            ; Enable Networking
    M586 P0 S1                         ; Enable HTTP
    M586 P1 S0                         ; Disable FTP
    M586 P2 S0                         ; Disable Telnet
    
    ; Drive direction
    M569 P0 S0                         ; Drive 0 X
    M569 P1 S0                         ; Drive 1 Y
    M569 P2 S1                         ; Drive 2 Z
    M569 P3 S0                         ; Drive 3 E0
    M569 P4 S0                         ; Drive 4 E1
    M569 P5 S1                         ; Drive 5 E2
    M569 P6 S1                         ; Drive 6 E3
    M569 P7 S0                         ; Drive 7 COUPLER
    M569 P8 S0                         ; Drive 8 UNUSED
    M569 P9 S0                         ; Drive 9 UNUSED
    
    M584 X0 Y1 Z2 C7 E3:4:5:6                                 ; Apply custom drive mapping
    M208 X-35:328.5 Y-49:243 Z0:300 C-45:360                 ; Set axis maxima & minima
    M92 X100 Y100 Z800 C91.022 E409:409:409:409             ; Set steps per mm assuming x16 microstepping  ;X100 Y100 Z1600 C91.022 E834:834:834:834 --- 04.12.2021 MISOM Z steps wrong
    M350 E16:16:16:16 I1                                     ; Configure microstepping with interpolation
    M350 C16 I10                                            ; Configure microstepping without interpolation
    M350 X16 Y16 Z16 I1                                        ; Configure microstepping with interpolation
    M566 X400 Y400 Z120 C2 E200:200:200:200                 ; M566 X400 Y400 Z120 C2 E2:2:2:2                            ; Set maximum instantaneous speed changes (mm/min)  ; M566 X400 Y400 Z8 C2 E2:2:2:2     --- 07.12.2021 MISOM z speed too low
    M203 X35000 Y35000 Z1200 C5000 E5000:5000:5000:5000        ; Set maximum speeds (mm/min)
    M201 X6000 Y6000 Z400 C500 E2500:2500:2500:2500            ; Set accelerations (mm/s^2)
    M906 X1800 Y1800 Z1330 I30                               ; Idle motion motors to 30%
    M906 E1000:1000:1000:1000 C500 I10                         ; Idle extruder motors to 10% (Extruder)
    
    ; Endstops
    M574 X1 Y1 S3                         ; Set X / Y endstop stall detection
    M574 C0 Z0                          ; No C Z endstop
    
    ; Z probe
    M558 P8 C"zstop" H3 F360 I0 T20000     ; Set Z probe type to switch, the axes for which it is used and the dive height + speeds
    G31 P200 X0 Y0 Z0                     ; Set Z probe trigger value, offset and trigger height
    M557 X10:290 Y20:180 S40             ; Define mesh grid
    
    ;Stall Detection
    M915 X Y S3 F0 H400 R4700                ; X / Y Axes
    
    ; Heaters
    M308 S0 P"bedtemp" Y"thermistor" A"Bed" T100000 B4138 C0         ; Set thermistor
    M950 H0 C"bedheat" T0                                            ; Bed heater
    M143 H0 S225                                                     ; Set temperature limit for heater 0 to 225C
    M140 H0                                                            ; Bed heater is heater 0
    
    M308 S1 P"e0temp" Y"thermistor" A"T0" T100000 B4725 C7.06e-8     ; Set thermistor
    M950 H1 C"e0heat" T1                                            ; Extruder 0 heater
    M143 H1 S305                                                     ; Set temperature limit for heater 1 to 300C
    
    M308 S2 P"e1temp" Y"thermistor" A"T1" T100000 B4725 C7.06e-8     ; Set thermistor
    M950 H2 C"e1heat" T2                                            ; Extruder 0 heater
    M143 H2 S305                                                     ; Set temperature limit for heater 2 to 300C
    
    M308 S3 P"duex.e2temp" Y"thermistor" A"T2" R2200 T100000 B4725 C7.06e-8 ;  P"duex.e2temp"    ;M308 S3 P"e2temp" Y"thermistor" A"T2" T100000 B4725 C7.06e-8     ; Set thermistor    --- 04.12.2021 MISOM
    M950 H3 C"duex.e2heat" T3                                        ; Extruder 0 heater
    M143 H3 S305                                                     ; Set temperature limit for heater 3 to 300C
    
    M308 S4 P"duex.e3temp" Y"thermistor" A"T3" R2200 T100000 B4725 C7.06e-8 ; P"duex.e3temp"   ;M308 S4 P"e3temp" Y"thermistor" A"T3" T100000 B4725 C7.06e-8     ; Set thermistor    --- 04.12.2021 MISOM
    M950 H4 C"duex.e3heat" T4                                        ; Extruder 0 heater
    M143 H4 S305                                                     ; Set temperature limit for heater 4 to 300C
    
    
    ; Tools
    M563 P0 S"T0" D0 H1 F2                     ; Define tool 0
    G10 P0 X0 Y0 Z0                         ; Reset tool 0 axis offsets
    G10 P0 R0 S0                             ; Reset initial tool 0 active and standby temperatures to 0C
    
    M563 P1 S"T1" D1 H2 F4                     ; Define tool 1
    G10 P1 X0 Y0 Z0                         ; Reset tool 1 axis offsets
    G10 P1 R0 S0                             ; Reset initial tool 1 active and standby temperatures to 0C
    
    M563 P2 S"T2" D2 H3 F6                     ; Define tool 2
    G10 P2 X0 Y0 Z0                         ; Reset tool 2 axis offsets
    G10 P2 R0 S0                             ; Reset initial tool 2 active and standby temperatures to 0C
    
    M563 P3 S"T3" D3 H4 F8                     ; Define tool 3
    G10 P3 X0 Y0 Z0                         ; Reset tool 3 axis offsets
    G10 P3 R0 S0                             ; Reset initial tool 3 active and standby temperatures to 0C
    
    ; Fans
    M950 F1 C"fan1"
    M950 F2 C"fan2"
    M950 F3 C"duex.fan3"
    M950 F4 C"duex.fan4"
    M950 F5 C"duex.fan5"
    M950 F6 C"duex.fan6"
    M950 F7 C"duex.fan7"
    M950 F8 C"duex.fan8"
    
    M106 P1 S255 H1 T70                ; T0 HE
    M106 P2 S0                        ; T0 PCF
    M106 P3 S255 H2 T70             ; T1 HE
    M106 P4 S0                        ; T1 PCF
    M106 P5 S255 H3 T70             ; T2 HE
    M106 P6 S0                         ; T2 PCF
    M106 P7 S255 H4 T70                ; T3 HE
    M106 P8 S0                        ; T3 PCF
    
    M593 F42.2                        ; cancel ringing at 42.2Hz (https://forum.e3d-online.com/threads/accelerometer-and-resonance-measurements-of-the-motion-system.3445/)
    ;M376 H15                        ; bed compensation taper
    
    ;tool offsets
    ; !ESTIMATED! offsets for:
    ; V6-tool: X-9 Y39 Z-5
    ; Volcano-tool: X-9 Y39 Z-13.5
    ; Hemera-tool: X20 Y43.5 Z-6
    
    G10 P0 X20.43 Y43.22 Z-5.79  ;G10 P0 X20 Y43.5 Z-5.08     ;  G10 P0 X20 Y43.5 Z-5.65                    ; T0     ;P0 X-9 Y39 Z-5 --- 04.12.2021 MISOM
    G10 P1 X20.5  Y43.75 Z-4.98  ;G10 P1 X19.75 Y43.6 Z-5.03     ;  G10 P1 X19.75 Y43.6 Z-5.56                ; T1     ;P1 X-9 Y39 Z-5 --- 04.12.2021 MISOM
    G10 P2 X21.12 Y43.21 Z-5.38  ;G10 P2 X20.35 Y43.5 Z-5.18  ;  G10 P2 X20.35 Y43.5 Z-5.36              ; T2     ;P2 X-9 Y39 Z-5 --- 04.12.2021 MISOM
    G10 P3 X20.57 Y43.02 Z-5.55  ;G10 P3 X19.75 Y43.5 Z-5.2   ;  G10 P3 X19.75 Y43.5 Z-5.52                ; T3     ;P3 X-9 Y39 Z-5 --- 04.12.2021 MISOM
    
    
    ;M572 D0 S0.2 ;M572 D0 S0.2                         ; pressure advance T0 --- Switched ON on 4.1.2022 MISOM
    ;M572 D1 S0.2 ;M572 D1 S0.2                         ; pressure advance T1 --- Switched ON on 4.1.2022 MISOM
    ;M572 D2 S0.2 ;M572 D2 S0.2                         ; pressure advance T2 --- Switched ON on 4.1.2022 MISOM
    ;M572 D3 S0.2 ;M572 D3 S0.2                         ; pressure advance T3 --- Switched ON on 4.1.2022 MISOM
    
    
    M575 P1 S1 B57600                    ; Enable LCD
    G29 S2                                ; disable mesh
    T-1                                    ; deselect tools
    
    M501                    ; load config-override.g
    
    
    Tfree1.g:

    Code:
    ; tfree1.g
    ; called when tool 1 is freed
    
    ;Drop the bed
    G91
    G1 Z4 F1000
    G90
    
    ;Purge nozzle
    M98 P"purge.g"
    
    ;Move In
    G53 G1 X78.8 Y150 F50000  ;G53 G1 X79.5 Y150 F50000 04.12.2021 MISOM
    G53 G1 X78.8 Y200 F50000  ;G53 G1 X79.5 Y200 F500000 4.12.2021 MISOM
    G53 G1 X78.8 Y220 F5000   ;G53 G1 X79.5 Y220 F500000 4.12.2021 MISOM
    G53 G1 X78.8 Y228.2 F5000 ;G53 G1 X79.5 Y242 F500000 4.12.2021 MISOM - Too far Y
    
    ;Open Coupler
    M98 P"/macros/Coupler - Unlock"
    
    ;fan off
    M106 P4 S0
    
    ;Move Out
    G53 G1 X78.8 Y175 F5000 ;G53 G1 X78.8 Y175 F5000 ;X79.5 Y175 F50000 04.12.2021 MISOM --- Too fast
     
  2. irumbo mateene

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    I have been having a similar issue where the tool head is dropped on pick up.. In my case it appears to be the coupler is not locking when it picks up the toolhead.

    Not sure if some one else has come across this. I am going to rebuild the coupler in case it may be a mechanical issue.

    This happens to me when I am swapping toolheads when printing with 2 filamemts. Rarely an issue with single filament print since you dont swap toolheads.

    Wondering if this could be a known issue or bug.

    Board: Duet WiFi 1.02 or later + DueX5 (duetwifi102)
    Firmware: RepRapFirmware for Duet 2 WiFi/Ethernet 2.05.1 (2020-02-09b1)
    Duet WiFi Server Version: 1.23

    this is my setup:
     
  3. Greg_The_Maker

    Greg_The_Maker Administrator
    Staff Member

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    The most common issue with failed tool pick-ups and dropped tool is bad alignment.

    Check the alignment, check the position of the tool in relation to the toolhead for pickup. Make sure the tool does not lean downwards and that the fan ducts are fitted. Adjust the scripts to match the tool position.

    Also no lubricant on the locking mechanisms can cause issues too. They should be lubricated with a grease. We use Magnalube.

    A good test, and one that I use to help diagnose issues is to manually hold the tool onto the tool head and do repeated lock / unlocks. If it's fine after 20-30 cycles its likely not the toolhead causing problems and more likely tool alignment.

    There is one other possibility, something is loose. Check the grub screws on the X/Y Motors first.
     
  4. Andy Cohen

    Andy Cohen Well-Known Member

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    This used to happen on my machine 1 out of 4 times. I fixed it by adding the limit stop switch and stopped using the current sensing.
     
    Greg_The_Maker likes this.
  5. MIKE_S0

    MIKE_S0 Member

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    Hello Andy,

    You only added end stops for X and Y, right ? Not for Z?
    I still have the issue that the tool drops on long prints with many changes. Currently, it happens mostly on T1. I have checked the alignment several times and do not see any issue with it.

    Now i will install the end stops for X and Y. Is there any manual / information on how to do this.
     
  6. Andy Cohen

    Andy Cohen Well-Known Member

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    I would doubt there are any docs beyond posts here. As I recall, Greg made a bracket for the X axis limit switch and posted it on this forum. I added only the limit switch for my X axis. The Y axis as well as the C drive, which is on the tool carriage, still use the stall/current reading. Z has always used the switch under the tool carriage as a limit switch for Z as well as a probe for "mesh" compensation.
    In my opinion only the X axis needs to have a bit more reliable accuracy to ensure that the tool pickup is in the correct X axis location.
     
  7. MIKE_S0

    MIKE_S0 Member

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    Sorry i meant the C not z.
    I downloaded the brackets already from Greg's Thingerverse. As far as I read, the installation and setup will be easy
    I have installed a Microscope (similar as in Rene Juraks Videos - but I installed it on a fixed position). After each calibration, the positions of the tools are slightly off. I hope the relatability will improve with the end stops.

    Having an end stop on C would be difficult, and I think the repeatability is not the problem with C. I was wondering if it is possible to give the C-Axis more current and therefore more power.
     
  8. MIKE_S0

    MIKE_S0 Member

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    Could you share me your config.g?
    You are also using rrf3?
     
  9. MIKE_S0

    MIKE_S0 Member

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    I installed the end stops and they work fine. Then I readjusted he tools positions and the first print was good, and it worked fine. I also have to highlight that the tool passion repeatability is much better now.

    But on the second pint after about 100 layers (maybe 20 tool changes on T1) T1 dropped again, and I'm where I started.

    Any suggestions why the T1 is not as reliable as the others ? I adjusted the position same as the others.
     
  10. Andy Cohen

    Andy Cohen Well-Known Member

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    Sorry,I’m still in RRF 2.X so my config file would be quite different. Current was not an issue for my for the small C stepper.

    I jogged each tool manually and got the exact locations for each parking place and used those accordingly in the tpre and tfree scripts. Have ya done that? Pickup and release for each tool has tight tolerances. No rubbing of the coupler on the plate is acceptable. The coupler has to travel in and out of each plate cleanly.

    IIRC there were a number of other things that I focused on to get reliability for tool pick. First be sure the brass coupling insert in the plate is still in all the way. Crashes can bump it a bit and knock its position out of where it needs to be in the tool plate. I posted about that awhile back. Next all your cables must be out of the way. The part that slides on the parking pins must move real easy and it should use the magnet in the parking bracket when the tool parks.
     
  11. MIKE_S0

    MIKE_S0 Member

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    Hello,

    I think i fixed it.
    Thanks again, I did the positioning many times and because the toolchanging was not working 1 out of 100, I think the position was not the problem.
    Push out the centerpiece of the all tool plates, clean it and pushed them back in, some of them have not been all the way in . But i think that was not the solution.

    I saw the "crash" live yesterday. The issue happened at the paring of the tool. He went in and hit the tool dock pins. So his position was not aligned with the pins. But, as mentioned, had adjusted the positions several times over.

    I put a delay time into the tfree1 (well, finally I did it on all tools).
    Code:
    G53 G1 X76.8 Y150 F50000 
    G4 P500                   ; Wait 500 ; msec     --- 2022.02.12
    ;Move In
    G53 G1 X76.8 Y200 F40000
    G53 G1 X76.8 Y220 F5000   
    G53 G1 X76.8 Y226.6 F5000 ;50000 Too fast Y
    Since this modification, it runs stable and reliable.

    I guess the next step is to look ant the deceleration. But step by step.
     

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