Problems when homing delta printer

So I have been working on a problem that i just can not seem to figure out.

Still in the building stages of my delta printer, and when I home the printer I am getting some strange behavior. The carts move to the top and stop at the end stops as normal, they back off from the stops and do the recheck as they should, but then on the second check and back off. However, after that, there is a stream of the following message repeated in the log:

< Warning:Invalid delta coordinate - move ignored

then there is this one:

< Error:No move in delta segment with > 1 segment. This should never happen and may cause a problem!

Finally the real odd part is that then i get a read back of the homed coordinates:

< X:1.17 Y:42656.31 Z:855.00 E:NAN

The X and Y coordinates are never the same but always in the same range. X being small around 1 mm, and then y being large in the 42000mm range. The z coordinate is correct.

The printer then locks up and does nothing until I reset it.

I have tried a ton of combinations. So I am not sure if there is any point in posting my specific printer settings in the host software. below are my firmware settings. I am happy to provide any info that might help. I am so stuck, i feel like it should be working.

/** Number of extruders. Maximum 6 extruders. */
#define NUM_EXTRUDER 0



#define MOTHERBOARD 35

#include "pins.h"

#define DRIVE_SYSTEM 3

// ##########################################################################################
// ##                               Calibration                                            ##
// ##########################################################################################

/** Drive settings for the Delta printers
*/
#if DRIVE_SYSTEM==3
    // ***************************************************
    // *** These parameter are only for Delta printers ***
    // ***************************************************

/** \brief Delta drive type: 0 - belts and pulleys, 1 - filament drive */
#define DELTA_DRIVE_TYPE 0

#if DELTA_DRIVE_TYPE == 0
/** \brief Pitch in mm of drive belt. GT2 = 2mm */
#define BELT_PITCH 2
/** \brief Number of teeth on X, Y and Z tower pulleys */
#define PULLEY_TEETH 20
#define PULLEY_CIRCUMFERENCE (BELT_PITCH * PULLEY_TEETH)
#elif DELTA_DRIVE_TYPE == 1
/** \brief Filament pulley diameter in milimeters */
#define PULLEY_DIAMETER 10
#define PULLEY_CIRCUMFERENCE (PULLEY_DIAMETER * 3.1415927)
#endif

/** \brief Steps per rotation of stepper motor */
#define STEPS_PER_ROTATION 200

/** \brief Micro stepping rate of X, Y and Y tower stepper drivers */
#define MICRO_STEPS 32

// Calculations
#define AXIS_STEPS_PER_MM ((float)(MICRO_STEPS * STEPS_PER_ROTATION) / PULLEY_CIRCUMFERENCE)
#define XAXIS_STEPS_PER_MM AXIS_STEPS_PER_MM
#define YAXIS_STEPS_PER_MM AXIS_STEPS_PER_MM
#define ZAXIS_STEPS_PER_MM AXIS_STEPS_PER_MM
#else
// *******************************************************
// *** These parameter are for all other printer types ***
// *******************************************************

/** Drive settings for printers with cartesian drive systems */
/** \brief Number of steps for a 1mm move in x direction.
For xy gantry use 2*belt moved!
Overridden if EEPROM activated. */
#define XAXIS_STEPS_PER_MM 98.425196
/** \brief Number of steps for a 1mm move in y direction.
For xy gantry use 2*belt moved!
Overridden if EEPROM activated.*/
#define YAXIS_STEPS_PER_MM 98.425196
/** \brief Number of steps for a 1mm move in z direction  Overridden if EEPROM activated.*/
#define ZAXIS_STEPS_PER_MM 2560
#endif


// ##########################################################################################
// ##                            Endstop configuration                                     ##
// ##########################################################################################

/* By default all endstops are pulled up to HIGH. You need a pullup if you
use a mechanical endstop connected with GND. Set value to false for no pullup
on this endstop.
*/
#define ENDSTOP_PULLUP_X_MIN true
#define ENDSTOP_PULLUP_Y_MIN true
#define ENDSTOP_PULLUP_Z_MIN true
#define ENDSTOP_PULLUP_X_MAX true
#define ENDSTOP_PULLUP_Y_MAX true
#define ENDSTOP_PULLUP_Z_MAX true

//set to true to invert the logic of the endstops
#define ENDSTOP_X_MIN_INVERTING true
#define ENDSTOP_Y_MIN_INVERTING true
#define ENDSTOP_Z_MIN_INVERTING true
#define ENDSTOP_X_MAX_INVERTING true
#define ENDSTOP_Y_MAX_INVERTING true
#define ENDSTOP_Z_MAX_INVERTING true

// Set the values true where you have a hardware endstop. The Pin number is taken from pins.h.

#define MIN_HARDWARE_ENDSTOP_X false
#define MIN_HARDWARE_ENDSTOP_Y false
#define MIN_HARDWARE_ENDSTOP_Z false
#define MAX_HARDWARE_ENDSTOP_X true
#define MAX_HARDWARE_ENDSTOP_Y true
#define MAX_HARDWARE_ENDSTOP_Z true

//If your axes are only moving in one direction, make sure the endstops are connected properly.
//If your axes move in one direction ONLY when the endstops are triggered, set ENDSTOPS_INVERTING to true here



//// ADVANCED SETTINGS - to tweak parameters

// For Inverting Stepper Enable Pins (Active Low) use 0, Non Inverting (Active High) use 1
#define X_ENABLE_ON 0
#define Y_ENABLE_ON 0
#define Z_ENABLE_ON 0

// Disables axis when it's not being used.
#define DISABLE_X false
#define DISABLE_Y false
#define DISABLE_Z false
#define DISABLE_E false

// Inverting axis direction
#define INVERT_X_DIR false
#define INVERT_Y_DIR false
#define INVERT_Z_DIR false

//// ENDSTOP SETTINGS:
// Sets direction of endstops when homing; 1=MAX, -1=MIN
#define X_HOME_DIR 1
#define Y_HOME_DIR 1
#define Z_HOME_DIR 1

// Delta robot radius endstop
#define max_software_endstop_r true

//If true, axis won't move to coordinates less than zero.
#define min_software_endstop_x false
#define min_software_endstop_y false
#define min_software_endstop_z false

//If true, axis won't move to coordinates greater than the defined lengths below.
#define max_software_endstop_x false
#define max_software_endstop_y false
#define max_software_endstop_z false

// If during homing the endstop is reached, how many mm should the printer move back for the second try
#define ENDSTOP_X_BACK_MOVE 5
#define ENDSTOP_Y_BACK_MOVE 5
#define ENDSTOP_Z_BACK_MOVE 5

// For higher precision you can reduce the speed for the second test on the endstop
// during homing operation. The homing speed is divided by the value. 1 = same speed, 2 = half speed
#define ENDSTOP_X_RETEST_REDUCTION_FACTOR 2
#define ENDSTOP_Y_RETEST_REDUCTION_FACTOR 2
#define ENDSTOP_Z_RETEST_REDUCTION_FACTOR 2

// When you have several endstops in one circuit you need to disable it after homing by moving a
// small amount back. This is also the case with H-belt systems.
#define ENDSTOP_X_BACK_ON_HOME -1
#define ENDSTOP_Y_BACK_ON_HOME -1
#define ENDSTOP_Z_BACK_ON_HOME -1

// You can disable endstop checking for print moves. This is needed, if you get sometimes
// false signals from your endstops. If your endstops don't give false signals, you
// can set it on for safety.
#define ALWAYS_CHECK_ENDSTOPS true

// maximum positions in mm - only fixed numbers!
// For delta robot Z_MAX_LENGTH is the maximum travel of the towers and should be set to the distance between the hotend
// and the platform when the printer is at its home position.
// If EEPROM is enabled these values will be overidden with the values in the EEPROM
#define X_MAX_LENGTH 400
#define Y_MAX_LENGTH 400
#define Z_MAX_LENGTH 855

// Coordinates for the minimum axis. Can also be negative if you want to have the bed start at 0 and the printer can go to the left side
// of the bed. Maximum coordinate is given by adding the above X_MAX_LENGTH values.
#define X_MIN_POS 0
#define Y_MIN_POS 0
#define Z_MIN_POS 0

// ##########################################################################################
// ##                           Movement settings                                          ##
// ##########################################################################################

// Microstep setting (Only functional when stepper driver microstep pins are connected to MCU. Currently only works for RAMBO boards
#define MICROSTEP_MODES {8,8,8,8,8} // [1,2,4,8,16]

// Motor Current setting (Only functional when motor driver current ref pins are connected to a digital trimpot on supported boards)
#if MOTHERBOARD==301
#define MOTOR_CURRENT {135,135,135,135,135} // Values 0-255 (RAMBO 135 = ~0.75A, 185 = ~1A)
#elif MOTHERBOARD==12
#define MOTOR_CURRENT {35713,35713,35713,35713,35713} // Values 0-65535 (3D Master 35713 = ~1A)
#endif

/** \brief Number of segments to generate for delta conversions per second of move
*/
#define DELTA_SEGMENTS_PER_SECOND_PRINT 150 // Move accurate setting for print moves
#define DELTA_SEGMENTS_PER_SECOND_MOVE 50 // Less accurate setting for other moves

// Delta settings
#if DRIVE_SYSTEM==3
/** \brief Delta rod length
*/
#define DELTA_DIAGONAL_ROD 482 // mm


/*  =========== Parameter essential for delta calibration ===================

            C, Y-Axis
            |                        |___| CARRIAGE_HORIZONTAL_OFFSET
            |                        |   \
            |_________ X-axis        |    \
           / \                       |     \  DELTA_DIAGONAL_ROD
          /   \                             \
         /     \                             \    Carriage is at printer center!
         A      B                             \_____/
                                              |--| END_EFFECTOR_HORIZONTAL_OFFSET
                                         |----| DELTA_RADIUS
                                     |-----------| PRINTER_RADIUS

    Column angles are measured from X-axis counterclockwise
    "Standard" positions: alpha_A = 210, alpha_B = 330, alpha_C = 90
*/

/** \brief column positions - change only to correct build imperfections! */
#define DELTA_ALPHA_A 210
#define DELTA_ALPHA_B 330
#define DELTA_ALPHA_C 90

/** Correct radius by this value for each column. Perfect builds have 0 everywhere. */
#define DELTA_RADIUS_CORRECTION_A 0
#define DELTA_RADIUS_CORRECTION_B 0
#define DELTA_RADIUS_CORRECTION_C 0

/** Correction of the default diagonal size. Value gets added.*/
#define DELTA_DIAGONAL_CORRECTION_A 0
#define DELTA_DIAGONAL_CORRECTION_B 0
#define DELTA_DIAGONAL_CORRECTION_C 0

/** Max. radius the printer should be able to reach. */
#define DELTA_MAX_RADIUS 200


/** \brief Horizontal offset of the universal joints on the end effector (moving platform).
*/
#define END_EFFECTOR_HORIZONTAL_OFFSET 33

/** \brief Horizontal offset of the universal joints on the vertical carriages.
*/
#define CARRIAGE_HORIZONTAL_OFFSET 18

/** \brief Printer radius in mm, measured from the center of the print area to the vertical smooth rod.
*/
#define PRINTER_RADIUS 175

/** Remove comment for more precise delta moves. Needs a bit more computation time. */
//#define EXACT_DELTA_MOVES

/**  \brief Horizontal distance bridged by the diagonal push rod when the end effector is in the center. It is pretty close to 50% of the push rod length (250 mm).
*/
//#define DELTA_RADIUS (PRINTER_RADIUS-END_EFFECTOR_HORIZONTAL_OFFSET-CARRIAGE_HORIZONTAL_OFFSET)
#define DELTA_RADIUS 213
/* ========== END Delta calibation data ==============*/

/** When true the delta will home to z max when reset/powered over cord. That way you start with well defined coordinates.
If you don't do it, make sure to home first before your first move.
*/
#define DELTA_HOME_ON_POWER false

/** To allow software correction of misaligned endstops, you can set the correction in steps here. If you have EEPROM enabled
you can also change the values online and autoleveling will store the results here. */
#define DELTA_X_ENDSTOP_OFFSET_STEPS 0
#define DELTA_Y_ENDSTOP_OFFSET_STEPS 0
#define DELTA_Z_ENDSTOP_OFFSET_STEPS 0


/** \brief Experimental calibration utility for delta printers
*/
#define SOFTWARE_LEVELING

#endif
//#if DRIVE_SYSTEM == 4 // ========== Tuga special settings =============
/* Radius of the long arm in mm. */
//#define DELTA_DIAGONAL_ROD 240
//#endif
//   ========== END Tuga special settings =============

/** \brief Number of delta moves in each line. Moves that exceed this figure will be split into multiple lines.
Increasing this figure can use a lot of memory since 7 bytes * size of line buffer * MAX_SELTA_SEGMENTS_PER_LINE
will be allocated for the delta buffer. With defaults 7 * 16 * 22 = 2464 bytes. This leaves ~1K free RAM on an Arduino
Mega. Used only for nonlinear systems like delta or tuga. */
#define MAX_DELTA_SEGMENTS_PER_LINE 22

/** After x seconds of inactivity, the stepper motors are disabled.
    Set to 0 to leave them enabled.
    This helps cooling the Stepper motors between two print jobs.
    Overridden if EEPROM activated.
*/
#define STEPPER_INACTIVE_TIME 90
/** After x seconds of inactivity, the system will go down as far it can.
    It will at least disable all stepper motors and heaters. If the board has
    a power pin, it will be disabled, too.
    Set value to 0 for disabled.
    Overridden if EEPROM activated.
*/
#define MAX_INACTIVE_TIME 0
/** Maximum feedrate, the system allows. Higher feedrates are reduced to these values.
    The axis order in all axis related arrays is X, Y, Z
     Overridden if EEPROM activated.
    */
#define MAX_FEEDRATE_X 200
#define MAX_FEEDRATE_Y 200
#define MAX_FEEDRATE_Z 200

/** Home position speed in mm/s. Overridden if EEPROM activated. */
#define HOMING_FEEDRATE_X 200
#define HOMING_FEEDRATE_Y 200
#define HOMING_FEEDRATE_Z 200

/** Set order of axis homing. Use HOME_ORDER_XYZ and replace XYZ with your order. */
#define HOMING_ORDER HOME_ORDER_ZXY
/* If you have a backlash in both z-directions, you can use this. For most printer, the bed will be pushed down by it's
own weight, so this is nearly never needed. */
#define ENABLE_BACKLASH_COMPENSATION false
#define Z_BACKLASH 0
#define X_BACKLASH 0
#define Y_BACKLASH 0

/** Comment this to disable ramp acceleration */
#define RAMP_ACCELERATION 1

/** If your stepper needs a longer high signal then given, you can add a delay here.
The delay is realized as a simple loop wasting time, which is not available for other
computations. So make it as low as possible. For the most common drivers no delay is needed, as the
included delay is already enough.
*/
#define STEPPER_HIGH_DELAY 0

/** The firmware can only handle 16000Hz interrupt frequency cleanly. If you need higher speeds
a faster solution is needed, and this is to double/quadruple the steps in one interrupt call.
This is like reducing your 1/16th microstepping to 1/8 or 1/4. It is much cheaper then 1 or 3
additional stepper interrupts with all it's overhead. As a result you can go as high as
40000Hz.
*/
#define STEP_DOUBLER_FREQUENCY 12000
/** If you need frequencies off more then 30000 you definitely need to enable this. If you have only 1/8 stepping
enabling this may cause to stall your moves when 20000Hz is reached.
*/
#define ALLOW_QUADSTEPPING true
/** If you reach STEP_DOUBLER_FREQUENCY the firmware will do 2 or 4 steps with nearly no delay. That can be too fast
for some printers causing an early stall.

*/
#define DOUBLE_STEP_DELAY 1 // time in microseconds

/** The firmware supports trajectory smoothing. To achieve this, it divides the stepsize by 2, resulting in
the double computation cost. For slow movements this is not an issue, but for really fast moves this is
too much. The value specified here is the number of clock cycles between a step on the driving axis.
If the interval at full speed is below this value, smoothing is disabled for that line.*/
#define MAX_HALFSTEP_INTERVAL 1999

//// Acceleration settings

/** \brief X, Y, Z max acceleration in mm/s^2 for printing moves or retracts. Make sure your printer can go that high!
 Overridden if EEPROM activated.
*/
#define MAX_ACCELERATION_UNITS_PER_SQ_SECOND_X 1000
#define MAX_ACCELERATION_UNITS_PER_SQ_SECOND_Y 1000
#define MAX_ACCELERATION_UNITS_PER_SQ_SECOND_Z 100

/** \brief X, Y, Z max acceleration in mm/s^2 for travel moves.  Overridden if EEPROM activated.*/
#define MAX_TRAVEL_ACCELERATION_UNITS_PER_SQ_SECOND_X 2000
#define MAX_TRAVEL_ACCELERATION_UNITS_PER_SQ_SECOND_Y 2000
#define MAX_TRAVEL_ACCELERATION_UNITS_PER_SQ_SECOND_Z 100

/** \brief Maximum allowable jerk.

Caution: This is no real jerk in a physical meaning.

The jerk determines your start speed and the maximum speed at the join of two segments.
Its unit is mm/s. If the printer is standing still, the start speed is jerk/2. At the
join of two segments, the speed difference is limited to the jerk value.

Examples:
For all examples jerk is assumed as 40.

Segment 1: vx = 50, vy = 0
Segment 2: vx = 0, vy = 50
v_diff = sqrt((50-0)^2+(0-50)^2) = 70.71
v_diff > jerk => vx_1 = vy_2 = jerk/v_diff*vx_1 = 40/70.71*50 = 28.3 mm/s at the join

Segment 1: vx = 50, vy = 0
Segment 2: vx = 35.36, vy = 35.36
v_diff = sqrt((50-35.36)^2+(0-35.36)^2) = 38.27 < jerk
Corner can be printed with full speed of 50 mm/s

Overridden if EEPROM activated.
*/
#define MAX_JERK 20.0
#define MAX_ZJERK 0.3

/** \brief Number of moves we can cache in advance.

This number of moves can be cached in advance. If you wan't to cache more, increase this. Especially on
many very short moves the cache may go empty. The minimum value is 5.
*/
#define MOVE_CACHE_SIZE 16

/** \brief Low filled cache size.

If the cache contains less then MOVE_CACHE_LOW segments, the time per segment is limited to LOW_TICKS_PER_MOVE clock cycles.
If a move would be shorter, the feedrate will be reduced. This should prevent buffer underflows. Set this to 0 if you
don't care about empty buffers during print.
*/
#define MOVE_CACHE_LOW 10
/** \brief Cycles per move, if move cache is low.

This value must be high enough, that the buffer has time to fill up. The problem only occurs at the beginning of a print or
if you are printing many very short segments at high speed. Higher delays here allow higher values in PATH_PLANNER_CHECK_SEGMENTS.
*/
#define LOW_TICKS_PER_MOVE 250000

In case anyone is interested, I also started a discussion about this, here: [groups.google.com]

There were a couple replies and a lot more information was provided as a result, but still no solution. Any ideas would be greatly appreciated.

In the mean while I might try marlin just to see if it gets me any further.

Thanks.

Edited 1 time(s). Last edit at 08/29/2014 01:35AM by cream.

Hi cream,

I have recently installed Repetier firmware and wrote a log here.

Perhaps you can try some of 'my' settings and see if that changes anything..?

Oh, your message is quite old, did you get it to run with Repetier or are you on Marlin now?

Edited 1 time(s). Last edit at 10/09/2014 05:46AM by 3D-ES.

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