Random hangs during prints

Controllers Smoothie
1

I’m using the Smoothieboard to run a 3D printer, and I’m running into an issue where I’m getting random hangs during print jobs. It can happen immediately, or it can happen six hours into a long print. The same file will sometimes run fine, and sometimes hang. The location of the hang is not consistent.

I can’t past links yet, so I’m going to drop my config file and some terminal logs here. Apologize for the length.

This is what the terminal log looks like when it hangs. Suddenly I start seeing responses that look like gibberish. Octoprint can’t parse it, and printing stops. This particular chunk of terminal code is from after doing a system restart on Octoprint. Nothing will cause the Smoothieboard to reconnect again until I do a full power cycle on the machine, taking everything down. Then it works again as normal.

Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5
Baudrate test retry: 4
Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5
Baudrate test retry: 3
Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5
Baudrate test retry: 2
Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5
Baudrate test retry: 1
Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5
Baudrate test retry: 0
Send: N0 M110 N0*125
Recv: $T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5$T050c:ffffffff;0d:187f0010;0e:4bc70000;0f:4ac70000;#b5

And here’s my config file!

# Smoothieboard configuration file
# NOTE Lines must not exceed 132 characters, and '#' characters mean what follows is ignored
## Robot module configurations : general handling of movement G-codes and slicing into moves


Basic motion configuration


default_feed_rate                            4000             # Default speed (mm/minute) for G1/G2/G3 moves

default_seek_rate                            4000             # Default speed (mm/minute) for G0 moves

mm_max_arc_error                             0.01             # The maximum error for line segments that divide arcs 0 to disable

# note it is invalid for both the above be 0

# if both are used, will use largest segment length based on radius



Arm solution configuration : Cartesian robot. Translates mm positions into stepper positions



Se


alpha_steps_per_mm                           320              # Steps per mm for alpha ( X ) stepper

beta_steps_per_mm                            320              # Steps per mm for beta ( Y ) stepper

gamma_steps_per_mm                           3200             # Steps per mm for gamma ( Z ) stepper

arm_solution                     cartesian          #



Planner module configuration : Look-ahead and acceleration configuration



See


planner_queue_size                 32              #

acceleration                                 1000             # Acceleration in mm/second/second.

z_acceleration                               500              # Acceleration for Z only moves in mm/s^2, 0 uses acceleration which is the default. DO NOT SET ON A DELTA

junction_deviation                           0.08             # See

z_junction_deviation                         0                # For Z only moves, -1 uses junction_deviation, zero disables junction_deviation on z moves DO NOT SET ON A DELTA

#alpha_acceleration                 500          #

#beta_acceleration                 2000          #



Cartesian axis speed limits


x_axis_max_speed                             30000            # Maximum speed in mm/min

y_axis_max_speed                             30000            # Maximum speed in mm/min

z_axis_max_speed                             300              # Maximum speed in mm/min



Stepper module configuration



Pins are defined as  ports, and pin numbers, appending “!” to the number will invert a pin



See


alpha_step_pin                               2.0              # Pin for alpha stepper step signal

alpha_dir_pin                                0.5!              # Pin for alpha stepper direction, add ‘!’ to reverse direction

alpha_en_pin                                 0.4              # Pin for alpha enable pin

alpha_current                                1.4              # X stepper motor current

alpha_max_rate                               30000.0        # Maximum rate in mm/min


beta_step_pin                                2.1              # Pin for beta stepper step signal

beta_dir_pin                                 0.11             # Pin for beta stepper direction, add ‘!’ to reverse direction

beta_en_pin                                  0.10             # Pin for beta enable

beta_current                                 0.7              # Y stepper motor current

beta_max_rate                                30000.0        # Maxmimum rate in mm/min


gamma_step_pin                               2.2              # Pin for gamma stepper step signal

gamma_dir_pin                                0.20!            # Pin for gamma stepper direction, add ‘!’ to reverse direction

gamma_en_pin                                 0.19             # Pin for gamma enable

gamma_current                                1.2              # Z stepper motor current

gamma_max_rate                               300.0            # Maximum rate in mm/min



Extruder module configuration



See


extruder.hotend.enable                          true          # Whether to activate the extruder module at all. All configuration is ignored if false

extruder.hotend.steps_per_mm                    1390           # Steps per mm for extruder stepper

extruder.hotend.default_feed_rate               600           # Default rate ( mm/minute ) for moves where only the extruder moves

extruder.hotend.acceleration                    500           # Acceleration for the stepper motor mm/sec²

extruder.hotend.max_speed                       50            # Maximum speed in mm/s


extruder.hotend.step_pin                        2.3           # Pin for extruder step signal

extruder.hotend.dir_pin                         0.22          # Pin for

Thanks so much for the help. It’s a great board and a great system, just seeing weird behavior.

Imported from wikidot

2

Have you got the Webserver running?

3

I don’t connect directly to the board. I connect to a host that runs Octoprint. Is there some value in connecting directly to the board in this instance? If so, what should I be looking for?

4

which method do you attach octoprint to smoothie?
via USB or ethernet?
I only tried it via ethernet, but had some hanging issues so i so i lost interest in it.
sorry i cant be of more assistance.

5

That config file is all kinds of wrong, please take the very latest configuration file from the wiki, and edit it *strictly* only as much as you need to get things to work the way you need.

The message you receive means there was a firmware crash, which I haven’t seen happen in the wild for like years now, something is very wrong here.

6

I also noticed that the LEDs are in a weird configuration. 2 and 4 are solid, 1 and 3 are off. I couldn’t find any reference to this in the troubleshooting guide, but there was a reference to it being a hardware fault and maybe a bad SD card here: on the Smoothieware Google support group.

I could try swapping out the SD card, I suppose, but that would seem to be odd since sometimes it prints all the way through just fine.