RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Someone on Reddit claims the resonance on their X motor is fixed after a replacement from Prusa:
That's consistent with what @raaz-2 found above, I'd say: Noise frequency correlated with the motor step frequency; only one axis (i.e. one motor) affected in his printer.
I would hope that properly calibrated phase stepping can offer a firmware solution which avoids a motor replacement, but the current preliminary implementation does not seem to have worked for everyone. Maybe there are types of motor flaws/tolerances which can't be compensated by adjusting the microstep spacing?
From a quality control standpoint. One would hope that Prusia is testing the assembled printers before they leave the factory to ensure any issues with the motors would be found before it shipped. Unfortunately, no idea what happens to people who are assembling the printer as it adds an entirely other level of troubleshooting issues related to the reported problems.
RE:
I believe with printers sent to them that have the problem they'll be able to update their QA testing for that issue. Since it does only affect a presumably smaller part of printers it'd be hard to catch if you don't know about it and your QA test didn't trigger the resonance.
The motor manufacturer is really the one that needs to step up their QA, maybe they did deliver a perfectly fine product some time ago and then changed something, either due to some parts not being available any more and/or being swapped for cheaper parts, then producing motors with a greater variation in quality.
However, that obviously doesn't mean Prusa shouldn't have to check the motors they get more thoroughly for that specific issue or maybe implement a whole new motor stress test to catch future issues.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Someone on Reddit claims the resonance on their X motor is fixed after a replacement from Prusa:
That's consistent with what @raaz-2 found above, I'd say: Noise frequency correlated with the motor step frequency; only one axis (i.e. one motor) affected in his printer.
I would hope that properly calibrated phase stepping can offer a firmware solution which avoids a motor replacement, but the current preliminary implementation does not seem to have worked for everyone. Maybe there are types of motor flaws/tolerances which can't be compensated by adjusting the microstep spacing?
Others have said it, It’s sounding like poor QC at the motor supplier. As we’re talking about vibrations or resonance, it’s highly probable that the affected motors are imbalanced leaving the factory. Unfortunately, no software updates will resolve that issue. There was a recent delay in printer shipments noted over the last couple weeks, support suggested a delay due to supply of a part. I’d be curious if this is partially related
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
My printer's kit will be sent in a week or so, I will keep you in touch if anything changed from my assembled one I had to return because of VFA and noise.
I cross my fingers so they noticed an issue and changed motor suppliers...
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Have Prusa acknowledged the issue? I'm sure I read somewhere they were working on a fix?
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Have Prusa acknowledged the issue? I'm sure I read somewhere they were working on a fix?
Ya, posted on reddit https://www.reddit.com/r/prusa3d/comments/1lf9mjv/psa_lets_address_the_vfa/
It's related to the VFAs rather than the noise but looking at some of the posts here, it seems probable that they are linked to some degree.
The post only goes as far as saying they are reviewing impacted printers to fix it, not that one has been found. There is a degree of justification that VFAs are normal part of 3d print in the post also, which no doubt is frustrating some owners who are badly impacted. That said I can also appreciate that because this is a known issue, Prusa are likely getting numerous complaints from hyper-vigilant customers who are seeing normal, low-level, VFAs in their shiny filament prints.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
During further test prints, I noticed that the noise only occurs during individual movements along the X and Y axes (both stepper motors are moving). During 45-degree movements where only the rear-right stepper is running, the printer is very, very quiet. During a 45-degree movement where only the left stepper is active, a slight noise can be heard. But as mentioned, when both steppers run simultaneously, it becomes incredibly loud. This noise consistently occurs at speeds between 78 mm/s and 84 mm/s. Much faster movements are significantly quieter. I have removed various Plexiglas and metal parts, but the noise persists. I also deactivated all stepper motors and manually moved the X-axis back and forth slowly, which reproduces the noise quite well. Even with two people, we couldn’t find the source of the problem.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
A Core One user with vibrations at 80 mm was instructed by support to loosen the six screws on the linear rail and then tighten them again until there was slight resistance.
Then tighten the screws another 45⁰, starting with the outer ones.
After that, his problem was solved. I can't test it because I don't have the problem.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Adjusting the screws on the X-axis didn't help. I've been in contact with Prusa for a few days now, but we haven't found a solution. I've already disassembled the printer to the point where only the structural parts necessary for operation remain. All metal and plastic parts have been removed, even from the extruder I've taken off everything that's not needed — but the noise is still very, very loud.
I share all my videos with you
https://drive.google.com/drive/folders/1CW2kKZ75bZbLT6SHATOWpt00bm0AFnDS
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Someone tested 45° angle movement and seems to be affected too: HERE
Does anybody figured it out with more tests?
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Someone tested 45° angle movement and seems to be affected too: HERE
Does anybody figured it out with more tests?
Hello, this is my Post.
I have written some Gcode by hand to test for this noise. Here is a link to the repository:
https://drive.google.com/drive/folders/1epmnqFpXVgUl-mzidXfKWP53O6eWrU7_?usp=drive_link
I tested them with my machine, they probably wont hurt your machine.
The Printhead stays cool and it wont extrude anything, the bed will be low enough to avoid scraping it.
It just Home moves the Printbed down and then starts the xy sequence
They all increase in speed.
In the first folder they start at 10 mm/s and increase every 2 rotations by 5 mm/s
in the second folder called from "10 to 55 mmps 1" they increase by one mm/s every rotation up to 55 mm/s
The one that says "each" moves both motors after one another, not at the same time. It creates 45° tilted square, like in the video.
It is good to test if one motor is especially bad. My Y motor seems to make worse noise than the x motor. They are both very loud though.
Support agreed to send me a replacement Y Stepper Motor.
The other two file names starting with "Both" move both motors in a non tilted square, together at the same time.
Since both motors work together to achieve the speed of the print head there are two versions
The one called "Both Motor Speed Non adjusted" is for seeing how the motors sound when moving the head at the exact amount of mm/s.
This is different from the motor speed in the each file. The motors are slower, so I expect the noise to happen at higher printhead move speeds.
Thats why I made an adjusted version where the square root of 2 is added to the f value in the g-code (the speed of the print head) to match the speed of each motor in the 45° "each" gcode file.
I hope this can help you test.
I have problems myself finding out where exactly the sound is coming form, but it has something to do with the motors, the belt
and how they interact with the pulleys.
further testing is required.
Maybe the g-code helps you to find the cause, or at least makes you aware of what speed range you need to avoid if you print at night.
The print range you need to avoid is the speed range of the Print head where it creates this noise in the "each" file and the "both non adjusted" file. avoiding this speed range will mean you wont cause this noise no mater the angle the print head moves in.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
I tried Phase Stepping calibration on my freshly built CORE One and it did nothing. Same resonance noises at 80mm/s. It drives me crazy.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
I've been in contact with Prusa for a while now. I've since been referred to a Core One specialist. I also provided all sources from YouTube and Reddit as references. However, so far it takes about a week for Prusa to respond, and they haven't acknowledged the issue yet.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
How is it possible they haven’t aknowledged this issue yet, there are several posts every day on Reddit about it…
That’s crazy!
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
I installed the latest firmware 6.3.4 today and performed phase stepping, but it didn’t help — when I print PETG in structural mode, it’s very loud."
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
For me, phase stepping made everything, apart from the (20) /40/80 mm/s resonances quieter.
Especially 130-350 mm/s went from a combined noise to basically just the Y-bearings making their "swoosh" sound.
These resonances seem to "simply" be the motor resonance + belt teeth exciting the XY-frame and linear rail.
It's mostly the motor resonance and phase stepping doesn't seem to help at all. It's probably mechanical inside the motor.. For me, the right motor is very loud, the left motor is almost quiet.
Interestingly, printing a 45° pattern also has way more ripple-VFA for the loud motor.
Nothing new, just summarising my older posts for the new ones. I hopefully gonna do the motor + pulley swap etc. in the first week of August and write a detailed protocol.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Prusa seem to be good at just keeping quiet on topics they have no response for (like shipping schedules!).
I honestly think they just do not know what's causing this - even after all this time.....
How is it possible they haven’t aknowledged this issue yet, there are several posts every day on Reddit about it…
That’s crazy!
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
I updated my Core One for the MMU3 and ran the Phase Stepping Calibration with the Accelerometer attached. Showed 80%+ reduction in resonance for X and Y. Printing now seems much quieter. 6.3.4RC is the firmware. Also using squash ball feet to prevent sound and vibration transfer to the table top.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
Some positive news at last!
I updated my Core One for the MMU3 and ran the Phase Stepping Calibration with the Accelerometer attached. Showed 80%+ reduction in resonance for X and Y. Printing now seems much quieter. 6.3.4RC is the firmware. Also using squash ball feet to prevent sound and vibration transfer to the table top.
RE: Prusa Core One not usable inhouse... Sorry, but the sound was to intensiv
A little more on the Phase stepping. Printing is quieter, but Rapid moves don't seem to be much quieter.