Loud clicking from bondtech gears while loading/unloading
 
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Worthing
(@worthing)
Eminent Member
Loud clicking from bondtech gears while loading/unloading

During the loading/unloading sequence, the extruder turns pretty rapidly, and the gears will make a loud clicking noise. It sorta sounds like they are catching on something, but I can't see anything they could be clipping. It only happens when there is no filament, as soon as the filament enters the extruder, the clicking stops.

It doesn't seem to have any negative effect, but it sounds very much like something is wrong.

Edit: Another clue is that is only seems to start midprint. I'm thinking that it's heat related. The extruder motor gets extremely hot (60+ C), and it's possible this is causing the gear to slightly expand or warp.

Posted : 29/03/2019 3:02 pm
PJR
 PJR
(@pjr)
Moderator
Re: Loud clicking from bondtech gears while loading/unloading

Probably the grub screw on the motor shaft catching on the Bondtech idler.

Had this a while ago before I printed and rebuilt the extruder (including re-aligning the Bondtech) when I was testing the firmware that keeps the Bondtech moving during tool change.

Peter

Please note: I do not have any affiliation with Prusa Research. Any advices given are offered in good faith. It is your responsibility to ensure that by following my advice you do not suffer or cause injury, damage…

Posted : 29/03/2019 4:16 pm
Worthing
(@worthing)
Eminent Member
Topic starter answered:
Re: Loud clicking from bondtech gears while loading/unloading


Probably the grub screw on the motor shaft catching on the Bondtech idler.

Had this a while ago before I printed and rebuilt the extruder (including re-aligning the Bondtech) when I was testing the firmware that keeps the Bondtech moving during tool change.

Peter

Interesting idea. Could be contributing to it, but I don't think it's the main cause in my case. The sound is constant, not just when the grub screw is facing the idler.

Posted : 29/03/2019 5:07 pm
bobstro
(@bobstro)
Illustrious Member
Re: Loud clicking from bondtech gears while loading/unloading


During the loading/unloading sequence, the extruder turns pretty rapidly, and the gears will make a loud clicking noise. It sorta sounds like they are catching on something, but I can't see anything they could be clipping. It only happens when there is no filament, as soon as the filament enters the extruder, the clicking stops.
Have you checked the fit of the Bondtech idler gear on the door of the extruder assembly? Might it or a related part be clicking when no filament is loaded, but separated once filament is inserted? Does the clicking continue with the tension screw loosened or the door opened?

My notes and disclaimers on 3D printing

and miscellaneous other tech projects
He is intelligent, but not experienced. His pattern indicates two dimensional thinking. -- Spock in Star Trek: The Wrath of Khan

Posted : 29/03/2019 5:16 pm
Worthing
(@worthing)
Eminent Member
Topic starter answered:
Re: Loud clicking from bondtech gears while loading/unloading



During the loading/unloading sequence, the extruder turns pretty rapidly, and the gears will make a loud clicking noise. It sorta sounds like they are catching on something, but I can't see anything they could be clipping. It only happens when there is no filament, as soon as the filament enters the extruder, the clicking stops.
Have you checked the fit of the Bondtech idler gear on the door of the extruder assembly? Might it or a related part be clicking when no filament is loaded, but separated once filament is inserted? Does the clicking continue with the tension screw loosened or the door opened?

The idler gear on the door seems to be clear of the door itself. Could possibly be catching on something inside the extruder, but I dont see any marks from where the gear rubbing on the plastic.

The sound lessens with the tensions screw loosened. At this point, I'm leaning towards the idea that the the main gear (on the stepper motor) is grinding against the extruder body on the left side (when viewing the printer from the front). I think that the pressure of the idler (on the tensions screws) is just enough to bend the gear ever so slightly to the left to catch on something.

I'll have to disassemble the extruder to get a look at what's going on behind the gear.

Posted : 29/03/2019 8:03 pm
jmone
(@jmone)
Reputable Member
Re: Loud clicking from bondtech gears while loading/unloading

I've developed the same issue, but I'm 24hrs into a 36hr print so reluctant to try to pause/restart to (printing via OctoPrint). It only happens in the Load/Unload when there is NO filament in the gears, once it is in there there is no issue.

Here is a short video showing what happens. At the beginning of the video you can hear and see the gear slipping, then the filament loads and it is all good.
https://jmone.org/nextcloud/index.php/s/GdCk96ZH8XFXA5n

Thanks
Nathan

Posted : 21/04/2019 6:14 am
cjbaar
(@cjbaar)
Active Member
RE: Loud clicking from bondtech gears while loading/unloading

FWIW, I have the same issue ever since upgrading to the latest firmware. And you said, it doesn't seem to affect loading, but sure sounds bad, and I wonder if it leads to premature stripping of the gears.

Posted : 26/04/2019 3:28 am
ad.lamy
(@ad-lamy)
Estimable Member
RE: Loud clicking from bondtech gears while loading/unloading

Had the same weird noise during my last 30 hours print, when removing the door I noticed rust powder in the extruder, I think since there is only one tensioner screw with an offset toward the gears, there is too much effort on these gears when no filament is engaged and it produce wear and noise.

I think they must change the fw, it's no necessary to activate the extruder motor all along the filament change process.

This post was modified 4 years ago by ad.lamy
Posted : 02/05/2019 7:47 am
cjbaar
(@cjbaar)
Active Member
RE: Loud clicking from bondtech gears while loading/unloading

@andre-l9 I agree. Seems like a lot of wasted energy and wear when the printer should know the filament is not loading yet.

Posted : 02/05/2019 8:33 pm
ad.lamy
(@ad-lamy)
Estimable Member
RE: Loud clicking from bondtech gears while loading/unloading

After an other 20 hours 5 colors print with this nasty noise and again plenty of rust powder in the extruder, I can't wait some solution from Prusa, I add a second tensioner screw to center the pressure in line of the filament pass.
Just reprint a modified extruder motor plate and an other idler door, and used the previous tension springs, they are softer. Works fine, no noise anymore. https://www.thingiverse.com/thing:3606597

Posted : 04/05/2019 8:54 am
Jon
 Jon
(@jon-9)
Eminent Member
RE: Loud clicking from bondtech gears while loading/unloading

I had a weird clicking noise as well, but it turned out to be the print fan vibrating in the holder.  I added a small piece of foam tape along the edge of the fan and everything quieted right up.  It only made the noise during the load and unload for some reason.  just a thought.

Posted : 09/05/2019 12:35 am
RakNoel
(@raknoel)
Eminent Member
RE: Loud clicking from bondtech gears while loading/unloading

I could put money on the problem being the bondtech lock-screw. I'm stuck with this problem myself right now.

The lock-screw comes loose after printing for about 3 hours, and sticks so far out it pushes the bondtech grears apart. Tightening the screw once again fixes the issue, but only for another 2-3 hours.

I had this EXACT same issue on my MMU2S but that was fixed when I re-calibrated the mmu tube length. I think the filament being pushed onto the bondtech is what knoks it loose, together with the heat

Posted : 10/05/2019 10:57 pm
jmone
(@jmone)
Reputable Member
RE: Loud clicking from bondtech gears while loading/unloading

I no longer seem to have the issue but FYI - I had to rebuild my Nextcloud server so the link to the video changed (and I can not edit my old post) - new link: https://jmone.org/jmonenextcloud/index.php/s/228FFGnPwSAddi7  

Posted : 02/06/2019 8:25 am
Casey
(@casey-2)
Estimable Member
RE: Loud clicking from bondtech gears while loading/unloading

I had fails in SINGLE mode.... Nothing but fails, same kind of clicking. However....

I got a wild hair and enabled stealth mode. It stopped rejecting the filament.

Well, NOW I have a new problem.... It loads, then it extrudes the purge line, then..... it acts like it wants a color change.
Well.... I  didn't insert a color change in the print that I sliced. I verified it. PrusaSlicer 2.0... But then, I opened the GCode in Notepad++... Sure enough, the GCode for color change was there! Here I was thinking the printer was hosing again. It was the GCODE output all along! Swap to Slic3r PE, no problems... Really not sure what condition produced that unrequested color change in PrusaSlicer.

Posted : 05/06/2019 12:34 am
FreelancerCal
(@freelancercal)
New Member
RE: Loud clicking from bondtech gears while loading/unloading

I hate to revive this old thread but I am having this same problem with my new MMU2S on my MK3S+ and am trying to find a solution or at least a explanation as to what is causing it. I have found only this thread and 1 other on this particular issue. Is there a fix for this? It is definitely not the grub screw for the gears as the issue with mine happens on the majority of the rotation of the extruder.

Posted : 12/04/2021 2:43 pm
RakNoel
(@raknoel)
Eminent Member
RE: Loud clicking from bondtech gears while loading/unloading

@freelancercal

Absolutely no problem with reviving older threads. I still have clicking from time to time, but I have become much better with my machine. The clicking is a general symptom of a wide array of issues, but knowing what it is might help you.

 

The clicking comes from the motor skipping a step, usually as its not able to push/pull the filament any more. This might be due to long ptfe tubes in wired angles (the enclosure is my issue), might also be one of the ptfe screws holding too tight. On the other end of the motor it might be an issue with the pipe guide, heatblock or nozzle being clogged. Even a partial clog might build up over time and create a lot of resistance.

 

Hope any of this helps

Posted : 12/04/2021 3:00 pm
FreelancerCal
(@freelancercal)
New Member
RE: Loud clicking from bondtech gears while loading/unloading

@raknoel

The issue on my printer only shows when it is unloaded and turning. (during the filament change process). So I do not think that the resistance on the filament is the issue. I posted a video of the problem on Facebook: https://www.facebook.com/1037651571/videos/10222025309355283/

Posted : 12/04/2021 3:14 pm
PrintingD
(@printingd)
Active Member
RE: Loud clicking from bondtech gears while loading/unloading

I am having the same problem here. Only seems to happen when the bond-tech is trying to get the filament as it is waiting for it to come in. But it starts before the MMU feeds it in, which makes little sense to me, particularly since there is an IR sensor that should know nothing is there. It sounds very crunchy and unhappy. Not sure what to do! As soon as filament is loaded into the extruder, no problems.

 

Posted : 03/05/2021 3:40 pm
Ornotermes
(@ornotermes)
New Member
RE: Loud clicking from bondtech gears while loading/unloading

I had the same issue right out of the box, figured out it's the extruder gears catching on eachother.

I ended up contacting the support and eventually they told me to lube the gear teeth, and it helped with the noise.

It's mentioned in the maintenance guide ( https://help.prusa3d.com/en/article/i3-printers-regular-maintenance_2072#extruder-driver-gear ), but not in the build instructions, so when you just built it and hear the noise you think something is wrong with it, not that you should go through the maintenance guide.

Posted : 05/05/2021 11:27 am
gdville
(@gdville)
New Member
RE: Loud clicking from bondtech gears while loading/unloading

I have a similar issue, out of the box after installing MMU2s on already functioning MK3S+.  First of all, idler does not align properly for feeding filament 1.  The selector aligns correcty, and pulley turns in correct direction for loading filament. After manually repositioning idler it will load to nozzle. But it appears that the MMU pulley motor is not synced to the extruder motor. They turn at different speeds druing load to nozzle. During 1st layer calibration they do not turn at the same time and sometimes even turn in opposite directions, leading to filament grinding and missed steps.

Posted : 18/05/2021 12:43 am
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