Loud buzzing during movement
Hello,
Is anyone else having a loud buzz/rattle during nextruder movement? It seems to be louder when traveling diagonally.
While it was printing I tried gently pushing on a bunch of stuff to see where it was coming from. I pushed on the screw indicated here, and the buzz goes away. I talked to support, which suggested lubricating that rod but it didn't help.
The next suggested step was tightening screws, so I started using my camera to take pictures of the area to find all the screws that might be impacted by pushing there. I noticed the screw in that set of four directly across from my arrow in the picture is completely stripped. I don't want to make it worse, but it seems probably likely that is the cause.
Has anyone else encountered something like this? I'm pretty bummed. It's easily twice as loud as my Prusa Mini, and I was hoping it would end up being quieter (especially in stealth mode). But with this buzzing you can hear it on the other side of the house.
RE: Loud buzzing during movement
Sorry, mis-spoke above. It is quieter when traveling diagonally. It seems to only make the buzz when traveling in Y (front-to-back). I don't think it makes any noise in X either, but it's hard to tell because of how the Core motion works.
RE: Loud buzzing during movement
Print in "Speed Modus" and the sound is not there...
RE: Loud buzzing during movement
Diagonally moves only one belt, straight X/Y moves both, which is why, when you push the nextruder forwards or backwards, it automatically moves diagonally.
But about your issue: what do you mean exactly by "the screw is stripped"? Is it tight, but the head is worn out or is it loose and it won't tighten, when turning clockwise?
Can you take it out? Buzzing noise sadly makes sense, if that screw is loose. The Y-bearing can move a little bit on one end and vibrate.
Could you record a video of it? Either way, I fear you'll need the Prusa Support to send you a new bracket. But you might end up sending them the printer (if you didn't buy the kit), since to replace that bracked, you'll need to take off quite a lot of parts..
RE: Loud buzzing during movement
Print in "Speed Modus" and the sound is not there...
I'm not sure what this means.
Diagonally moves only one belt, straight X/Y moves both, which is why, when you push the nextruder forwards or backwards, it automatically moves diagonally.
But about your issue: what do you mean exactly by "the screw is stripped"? Is it tight, but the head is worn out or is it loose and it won't tighten, when turning clockwise?
Can you take it out? Buzzing noise sadly makes sense, if that screw is loose. The Y-bearing can move a little bit on one end and vibrate.
Could you record a video of it? Either way, I fear you'll need the Prusa Support to send you a new bracket. But you might end up sending them the printer (if you didn't buy the kit), since to replace that bracked, you'll need to take off quite a lot of parts..
The screw head had very little to grab onto. It looked like it must have been destroyed during assembly. I was able to get it out by jamming the driver through a rubber band to get some extra grip.
After a few hours with support they want me to replace the right side linear bearing since I was able to get that screw out.
Videos:
https://youtube.com/shorts/Kh1NA4sLO0E?si=eIQUHQxKk27Sz8LU
RE: Loud buzzing during movement
Ouch, that sounds horrible!
Thanks for the video. Replaying the bearing + the U-Clamp and screw should do the job. It's just annoying to get the linear rod out of the CoreXY frame.
Keep us updated!
RE:
I do have noise like that on the X axis only movements. Very annoying. Sounds a bit like resonance.
RE:
It seems that the "phase stepping calibration" now implemented (but not officially released) in firmware 6.3.3 has worked for most users who tried it, and has made the Core One run quieter. Worth a try if your printer shows rough movements and resonances, I think.
You will need the optional accelerometer. Install it and execute G-code command "M1977" -- most easily done by "printing" a file which contains only this g-code. This should start the calibration wizard. The wizard has not been made available in the menus yet, because apparently it still fails for some printers; see the Github discussion. But it seems to work for most users, or otherwise it fails with an error message without doing any harm. Worst case you can always factory-reset the firmware settings.
RE: Loud buzzing during movement
Ouch, that sounds horrible!
Thanks for the video. Replaying the bearing + the U-Clamp and screw should do the job. It's just annoying to get the linear rod out of the CoreXY frame.
Keep us updated!
I'm actually pretty worried about that. They said there would be instructions. I've taken a peek inside and see no easy way to get that rod out without tearing down the entire printer. The kit assembly instructions show them doing that part before the housing is installed. I really don't want to completely disassemble the printer. I paid a lot extra for it to come assembled.
RE: Loud buzzing during movement
You definitely don't need to tear down the whole printer, but I'll check the manual later today.
I think you should be able to only take out one rear strut, loosen the rod-clamp. Then put the rear strut back in place and remove the front strut. Loosen the rod-clamp there too and then pull out the rod.
But I'm not sure what to do with the print head during that etc., so I'll have to check the assembly instructions and look at my own Core One..
RE: Loud buzzing during movement
I found that you can actually get to the front rod clamp screw by wiggling a hex key in from the other side with the filament panel taken off. It will be tedious loosening 1/8 turn at a time, but I think it will work. Then, I believe all screws on the rear clamp are accessible, so I should be able to loosen that front clamp and completely remove the rear one to get the bearing out.
As for the print head... I think if you just unscrew the linear bearing from the metal bracket (without removing the entire bracket itself), the entire gantry assembly including the print head will just rest on the top frame.
RE: Loud buzzing during movement
Well, I did the bearing replacement: no luck at all. It sounds exactly the same after.
I did find there's several "CoreONE buzzing" STLs now on Printables, so I tried one of those to get a better controlled test. You can hear it clearly buzz on diagonal movement in some directions. Then I made my own model that travels exclusively in that direction so that it just effectively buzzes constantly so I can try to find it. I printed several of these at 5 minutes each and found nothing obvious.
RE: Loud buzzing during movement
More and more testing seem to show that it could come from a bad motor. Someone tried to print and test (like you did you your videos) but without filament (to not waste material), and then he tested to unplug X or Y motor to try to isolate the noise, and in his case the resonance noise stopped when X motor was unpluged.
RE: Loud buzzing during movement
@gizmotoy -- I may have overlooked it in the thread, but have you tried the "M1977" G-code command to trigger a phase stepping calibration? While Prusa still has not released the calibration wizard, there seem to be significant improvements in firmware 6.3.3, and several users have reported that it did make their printer quieter. (Others have reported no significant effect, or the wizard terminating with an error message.) See the discussion on Github.
Worth a try, I think. You will need the accelerometer to run the calibration.
RE: Loud buzzing during movement
I haven't tried the M1977 thing yet but it's next on my list. I had zero luck getting to chat with support today. The waits were 40+ minutes and if you're not actively staring at that box it pulls you out of line due to "inactivity". I tried 3 times and never got through. I'm not sure what activity it wants me to do on a blank wait screen for 40 minutes.
RE: Loud buzzing during movement
I have the same buzzing sound and I had a kit printer so for sure there is nothing badly assembled. Happens on some directions only... Really strange and for me something start to resonate at certain speeds.
RE: Loud buzzing during movement
So I finally got a chance for another round with support.
We checked various things for play, loosened (sound is reduced) and tightened (sound is increased) belts. Next is they want to inspect all of the pulleys. Apparently this involves near complete disassembly of the machine. I've been trying to understand how the gantry comes apart to get at the belt retainers, removal of the steppers, and so forth. I'm not even sure I want to give this a try. It looks very complicated.
Pretty disappointed.
RE: Loud buzzing during movement
Another video, this time with the belts loosened 3 whole turns.
RE: Loud buzzing during movement
Have you tried disconnecting X motor then Y motor while printing (without filament) to see if a motor is involved?
RE: Loud buzzing during movement
I have not, but mine makes the noise even with both motors off and moving the extruder manually, so I don't know what disconnecting a motor would tell me that a manual test doesn't (at lower risk to the machine).