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Weirdness with Pings. Encoder Problem?

My Palette 2S, Octoprint hub and MK3S have been working flawlessly for almost a year. I recently started having problems with colors bleeding from one layer to the next creating entire layers with the wrong color. Strangely, successive pings during the time when the colors were swapping were exactly the same value up to eight times in a row, followed by over correction. (See attached images).

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I cleaned the encoder wheels with alcohol and re-calibrated SPC and PPM and printed an earbud. All pings were between 100.7 and 101.08, but again 4 successive pings were the exact same value and the colors did not print correctly.

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I’d really appreciate some help from @mosaicsupport on this issue. Since my last post I have reset my P2, recalibrated SPC and PPM and successfully printed key chains. Pings were 93% on the key chains. When I go to earbuds, I still get repeating ping values and improper colors.

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I created a small color disc calibration print and am seeing the same behavior.

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Transition lengths: 105mm weak, 150mm strong. These values have worked for me for the last year for countless prints. Something has changed. Please help

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Hi @madmax, thank you for sharing all of these details regarding this issue you are seeing. Would you be able to let us know:

  • What version of the Palette 2 plugin you are using?
  • What Octoprint version?
  • If you go to Settings > Preferences > Printer Profiles on your Palette menu, what is the current HM (ping average) saved to your printer profile?

I apologize to hear this is happening with your prints, happy to look into this further.

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Hi again @madmax, one more request actually! If you have any of the Octoprint and Mosaic logs that would be great as well.

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Hi! I have the same problem from yesterday, how can I fix that? I tried recalibrate but doesnt work…

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I am thinking… did you make any changes on canvas since yesterday? Thanks

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@aordono Thanks for the reply. Palette plugin version is 3.0.0. Octoprint 1.61 on Octopi .16 (Pi 3B). Ping average is 92.76% after initial key chain print. The web client won’t let me upload .log files so i posted the Mosaic.log and Octoprint.log files here https://drive.google.com/drive/folders/1...

The mosaic file is 633MB, but I haven’t printed anything since the disc i referenced in my last post, so that should be the last print activity in the log file.

My next thought was to rebuild my Octoprint image from scratch without unnecessary plugins to try to eliminate any serial comm issues.

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@aordono @mosaicsupport Any suggestions for my issue. I’m running out of things to try. So far:

1) Re-imaged OctoPi to v .18 and reloaded Octoprint 1.61. Only plugins are Canvas 3.0.3 and Palette 3.0.0

2) Switched out Raspberry Pi hardware and power supply

3) Verified that MK3S is accurately measuring filament by sending gcode to extrude 100mm and physically measuring the amount consumed. +/- 0.5mm based on ability to read a Sharpie mark with a ruler.

4) Verified extrusion multiplier by confirming thin wall thickness with calipers is same as the extrusion width setting in Canvas (.4mm)

5) Cleaned bowden gears and nozzle

6) Printed several perfect benchies in single color

I’m still getting color swapping on simple test prints and still seeing multiple successive pings of the exact same value. I’d like to determine if this is a problem with my Palette before the warranty expires.

Thanks

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Hey Danny, would you mind sharing the list of pings that you received? Also, when was the last time that you replaced the splice tube?

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Hi Jonny @jonnyyeu ,

Sorry I didn't see your comment. Splice tube was replaced about 1 week ago. I have shared pings, pictures and .log files here https://drive.google.com/drive/folders/1... with new files from yesterday.

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The lack of support is disturbing to say the least. I have a 2s pro myself with the exact same issues, and a 3 pro on preorder that I'm ready to cancel. They don't seem to support their product at all which considering the high price tag youd think these would come with support and be pretty trouble free. The 2 year warranty is useless if they don't actually support or back it up. Luckily I just got it a few weeks ago so I can file a claim with my credit card company and get my money back that way since they refuse to support or honor their warranty.

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My 2S has worked flawlessly for a year, but I haven't really been able to isolate the Palette as the problem. Typically, I've gotten pretty good support for minor issues and questions.

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Hi Emerson, we're sorry that you feel that we're not providing support, but we've been attempting to help solve your issues over Facebook and have been waiting for your feedback in order to proceed. Based on what you've shared, your pings are very low, meaning that either the calibration needs to be redone (as your printer is using much less filament than expected - mm3d.co/calibration-troubleshooting), or there could be something in the filament path that is causing less filament to be extruded (clogged nozzle, thin splices, etc.). I've made suggestions on how to improve your setup but haven't received any responses on the thread, specifically about the filament path and HM. It would be helpful if you provided us with some feedback in order for us to better understand your issue so that we can help to solve it.

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I have calibrated and recalibrated it several times. When I removed the palette from the equation my printer works flawlessly. I have my splice specs and they fell within tolerances per your response.

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Hi again @emersonsc, since we last checked in on Facebook, have you tried printing in connected mode with the new RPi and USB cable? Are you seeing the same ping issues with that new RPi setup?

If it is indeed a communication issue (since your splices are good), we can send a new IO board to you as well under the warranty coverage.

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Yes @aordono unfortunately same erratic pings. I even tried another USB cable. Does the I/O board cover the encoder wheel as well? I'm just wondering if it's not picking up the correct filament usage. I honestly don't know and am at a loss

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Hi again @madmax, I apologize for the delay as were just looking into this issue a bit more. I also want to quickly thank you for sharing what you tried since then, as this helps me to eliminate some of the other suggestions I had in mind.

These duplicated pings relate to either a communication error, or an extrusion issue. In the event that it is not a communication error, a duplicated ping can also happen when the ping comes in out of the expected bounds (this would be a missed ping if you were printing in accessory mode).

Some suggestions in case this is a communication issue:

- Try swapping out the USB cable between Palette and the hub for a new one.

- Minimizing any interference where possible. With your setup try checking if there are ways to reduce any static, or if there is the possibility that there are any magnets nearby.

- We could also send you a new IO board for your Palette.

With regards to any extrusion issues, since you already did e-steps calibration you could take a look at:
- Your splice tuning settings and the splices themselves. Have you observed any bulging/necking splices recently? A splice that is bulging/necking can lead to a ping being out of bounds. You can try measuring any recent splices with calipers, or share the splice tuning settings you have used recently.

Thank you again for your patience.

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@aordono thanks for your reply. As I mentioned, I switched out my complete Pi board to eliminate bad USB ports. However I did not change the cable. I will try that and I will raise my extrusion temp 5C to help minimize any potential nozzle clog issues. My splices look good. I have been using 3,-1,0 for a long time with no problems. I did recently switch out a splice tube. I’ll measure my latest ones, but they typically are not higher than 1.8mm. My filament runs on the thin side down to 1.70mm sometimes, but usually 1.73 to 1.75. There’s no magnetic interference as far as I can tell.

This morning I sat and watched the print for about an hour before going to work. I had 5 successive pings the same value but did not notice any slippage or under extrusion at the printer and the splice target began to drift and created a few layers of off color. After the 5 pings, it seemed to catch up. Thanks for your help.

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@aordono @jonnyyeu Thank you for all your help. In @aordono ‘s last post, she asked me if I had checked my USB cable. I had tested everything BUT the USB cable. Why would the cable be bad? Cables never go bad, they just sit there, right? So I looked at my USB cable and DOH! (*slaps forehead*). Here is a pic of my USB cable

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Since I replaced the cable I have made multiple perfect test prints in both Canvas and P2PP with ping variations on the order of +/- 0.5%. Thanks for the great support and your patience! Now I can get back to printing my dive bomber.

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-Danny

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Great ig you find the problem!! Do you have the stl of the disc with 3 colors to make test here in my palette? Thanks.

My palette always start well but little by little the pings go worse until it swap the colors…

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@espariz .stl’s attached. I made it in Fusion. It prints quickly with a small transition tower, uses about 10m of filament and generates about 20 pings. I use 100% infill. You can scale it larger for more pings. Look at your ping file carefully. If there are any repeating values, check your cable and and keep it away from power cords or power supplies. Good luck!

Color-Disc-v1_Color-Disc-v1_Body4_Color-Disc-v1.stlColor-Disc-v1_Color-Disc-v1_Body3_Color-Disc-v1.stlColor-Disc-v1_Color-Disc-v1_Body2_Color-Disc-v1.stlColor-Disc-v1_Color-Disc-v1_Body1_Color-Disc-v1.stl

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Thanks Danny! I will test with this

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@aordono @jonnyyeu I may have been prematurely optimistic. I printed at least 4 successful test prints after changing the cable, but experienced the problem again. The plane in the picture took 32 hours and generated 223 pings. With only a few hours left at ping 202 I started to get the repeating pings again. Could you please send me a new IO board? I’ve tried everything else I can think of. Thanks, Danny

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Hi @madmax , really sorry to hear about this. We'll arrange for the warranty replacement right away! I believe we already have your shipping information on file, please expect a confirmation email soon and let us know if anything needs to be changed for the order.

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@aordono Thanks very much

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Danny Milla will be eternally grateful.
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