Pruse extruder motor clicking/chugging independent of filament
I put together an i3 MK3S+ kit a couple days ago and managed to make two really good prints for my kids no problem (pic of boom box and of kitten).
However on starting a third print, the extruder motor started clicking and chugging (video). I first turned up the heat from 210 to 220, no change. I also did two cold pulls, both clean, no change.
I removed the filament entirely and ran a test and the extruder motor was still clicking, so it is not related to the filament being misaligned/partially jammed/overly tensioned. It seems like the motor itself has a problem? I've also reseated the connection to the board, no change. I don't imagine the wire itself has an issue that would cause this and not just a complete disconnect. Video of clicking extruder
The ticking is definitely from the motor itself, it ticks even without filament in place. The extruder motion should be smooth, but mine now ticks and "chugs" and the resulting imperfections are evident in the pic of the half-cube. Those little side features shift as I turned the print speed up mid-print to see how that affects the clicking. The clicking is constant rhythm in relation to print/extrusion speed. It's not random like it's catching on stuck filament or grinding the filament.
It bears repeating: the clicking occurs even without filament, is constant rate relative to print speed, and causes artifacts in the print. I need help! thank you!
RE: Pruse extruder motor clicking/chugging independent of filament
Open the Idler door and check the bondtech gear screw for tightness. Screws can often loosen on a brand-new printer.
https://help.prusa3d.com/article/checking-re-aligning-the-bondtech-gear-mk3s-mk2-5s_133176
wbr,
Karl
Statt zu klagen, dass wir nicht alles haben, was wir wollen, sollten wir lieber dankbar sein, dass wir nicht alles bekommen, was wir verdienen.
RE: Pruse extruder motor clicking/chugging independent of filament
Hello, thank you for the response! I've realigned the bondtech gear (it was not really out of alignment tbh) and tightened reasonably tight. The extruder still clicks. It progresses but the motor motion is not smooth and it is noisy. I've added a video of the extruder starting the first layer calibration run with no filament in the extruder (it is sticking out of the top but only to trigger the IR sensor to start the first layer calibration). You can see that the clicking is not due to resistance from the filament or misalignment (the screw comes into view with the flat side of the shaft). The motion and constant rate suggest to me an actual motor command or motor issue, but I'm not an expert here. I did flash a firmware update to the printer before the 2nd print, but that seemed successful.
When I manually move the extruder from the move axis->extruder menu setting, it's quite noisy and jerky but is able to rotate just fine. Here is another video of moving the extruder motor manually with no filament. I'm not sure if that jerky motion and noise is normal for this part, but the other axes are not as loud.
It still seems to me the issue is with the motor or software as there does not seem to be any mechanical impingement on the gear motion, it is just moving jerky on its own. I could tear down the head further to remove the motor and further isolate it, but I'm not sure that would be fruitful. Is it possible to plug the printer into a computer with the USB cord to get deeper diagnostics? Any help is appreciated, thank you!
RE: Pruse extruder motor clicking/chugging independent of filament
Either there is a foreign object near the stepper area or the stepper is defective.
I would contact Prusa support.
Just log in with your Prusa account and select the eshop. After a few seconds the chat window should appear on the lower right corner. If the chat window does not open, disable a possibly activated adblocker or try another browser.
wbr,
Karl
Statt zu klagen, dass wir nicht alles haben, was wir wollen, sollten wir lieber dankbar sein, dass wir nicht alles bekommen, was wir verdienen.
RE: Pruse extruder motor clicking/chugging independent of filament
Hello everybody. I have the Mk3 printer, since 2017, and this week, after all this time printing, i'm having the same issue than the video you send.
Let me tell you my friend, that it is a firmware problem. After the 3.13.1 firmware update, it started to do it.
You can check all the forums, and the github issues. It's a temperature sensor failing. I'll wait until the next firmware update.
The gear screw is tight as always the first day i assembled it
RE: Pruse extruder motor clicking/chugging independent of filament
Thank you for your help! I think I will disassemble the print head some to verify there are no foreign bodies where they can't be seen from the idler door. If after reassembling the print head it's still clicking I will elevate the issue to Support. Last picture is of a completed calibration cube with the uneven flow. It doesn't seem to have a problem with partial blockage that would cause a weak flow or failed print, just a bumpy surface from jerky motor motion.
RE: Pruse extruder motor clicking/chugging independent of filament
is it possible to roll back the firmware to 3.12? I could look into that
RE: Pruse extruder motor clicking/chugging independent of filament
I would downgrade to 3.11 (old thermal model protection).
https://github.com/prusa3d/Prusa-Firmware/releases#New_thermal_model_protection
wbr,
Karl
Statt zu klagen, dass wir nicht alles haben, was wir wollen, sollten wir lieber dankbar sein, dass wir nicht alles bekommen, was wir verdienen.
RE: Pruse extruder motor clicking/chugging independent of filament
Hello again everybody. I contacted support who suggested a test where I unplug the extruder motor from the board and plug it back into a different motor's port and then manually move that axis to drive the extruder motor and see if the same behavior occurs. I unplugged the extruder motor and Y axis motor and plugged the extruder motor into the Y axis port, and then manually moved the Y axis in the Settings menu to drive the extruder motor. The motor was whisper quiet: https://photos.app.goo.gl/GspN6xkESSVN8Z4V6
I plugged it back into the extruder port on the board and the horrible clicking returned: https://photos.app.goo.gl/fTUUkV91ZVMZTQCv5
I have rolled back the firmware to 3.10 (what was loaded on the board when I received the kit) and then 3.11 and neither firmware flash changed the behavior. Is there a more thorough reflashing or reformatting of the board memory to wipe out whatever is causing the clicking motion in the extruder signal? I am at a loss on how to fix this besides replacing the board entirely, but even that seems orthogonal to the problem and a firmware solution should exist.
I've alerted support to this new evidence that at least the extruder motor and cable seem OK based on its quiet function when plugged into the Y axis port. This test also ruled out mechanical blockage as the motor spins smoothly and quietly when in the Y axis port. The problem then seems to lie in the board or more likely the firmware. Still looking for any assistance on this, my printer is not very useful and quite noisy in its current state. Thanks!