1 Topic by Chapin (edited by Chapin 2015-01-30 23:36:20)

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Topic: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

So, I've had my Press working for about a week now. It seemed to be working well for the last week, so I decided to try to use Repetier-Host 1.0.6, following the instructions from SoliRyan found here: soliforum.com/post/80457/#p80457

After setting things up, everything seemed to be working except that when it would try to print, it was not extruding at all. I could however manually tell it to extrude.

Last night, wanting to get something to print, I went back to SoliPrint to try. Now when I try to tell it to extrude after it reaches temperature, it just makes a thumping noise. Retracting seems to work sometimes for short distances, but most of the time it seems like its just random movement or a horrendous buzz sound. I checked the extruder wheel set screw first thing, and its was definitely tight and set into the flat section of the stepper motor shaft.

Now, if I push the filament through the extruder while holding the tension wheel back, it extrudes from the nozzle, so its not a jam. I've checked through the forums for similar problems and could not find any that match my own experiences. So far I have tried the following:

  • Adjusting the extruder pot. - Both up and down, neither seem to have any affect.

  • Cleaned my nozzle, just in case. I was able to extrude by hand successfully afterwards.

  • I removed the extruder wheel completely - Just to verify that its not binding on anything, and the motor behaves the same.

I know I've not tried all that much, but I'm hoping someone has some clue what this might be. I was relatively happy with the things coming out of the printer so far, even if they were dust collectors so far!

Edit/Solution: To make it easier to find, here's the solution:

The cable connecting the motherboard to the extruder stepper motor itself had a bad connection. I had to solder the wire to the stepper side connector. I discovered it in the end due to input below, and testing continuity of each of the 4 conductors.

2 Reply by thatdecade

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

Remove the filament, does the wheel turn normally without thumping?

My first guess is a the temperature problem.

3 Reply by WelderDon

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I was having pretty much the same problem,  it wouldn't extrude unless I helped it. The motor would just make a continuous clunking noise and not rotate.  I emailed solidoodle and asked them about this.  While waiting for a response I messed around with the extruder temperature.  I increased the temperature to 265°c. It pretty much eliminated the problem! Solidoodle did get back to me and said to adjust the extruder pot (which you've already tried). I have not tried adjusting the pot yet, i will today.

4 Reply by Chapin

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

Yea, I do not think that its the extrusion temperature, mainly because the stepper motor is making the thump thump noise when the extruder gear is removed, so no resistance. I, however, did try setting the hot end temp to 265, letting it heat, and telling it to extrude to see if the motor would turn. It just kept making the same thumping noise.

I tried the pot again today as well. I raised the printer up and lowered the motherboard tray so I could get to it, then heated the head to 250, and told it to extrude. I started with the pot all the ways counterclockwise and the motor still made the same thumping noise. I then slowly turned it up and there was little effect. The thumping noise got a little louder as I turned, but there was no point that it stopped. I verified that the motor was not turning during this, just wiggling a little bit like it WANTED to turn.

5 Reply by CobbCrawler

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

With the printer off try turning the motor shaft by hand to make sure the bearing hasn't froze up but that's not likely. This sounds like the stepper is not communicating or a software problem to me, maybe go back to the software that was working to verify.

6 Reply by Chapin

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I tried this and the motor itself turns, with resistance of the coils inside.

This is occurring with both SoliPrint and Repetier-Host as well. Any time I tell the extruder stepper to extrude, it just thumps and jiggles a little like it want to turn but it can't.

I submitted a ticket with Solidoodle with everything I've tried so far. Maybe they'll have a suggestion or fix for this.

7 Reply by Fredjikrang

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

This just happened to me to. I probably have almost 100 hours printing, and now suddenly it won't extrude! So annoying! Chapin, if you figure it out, let me know!

8 Reply by cbud

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I'm also having the same problem - extruder motor thumping, but if I press (hard) on the filament it'll go through the nozzle no problem.

Does anyone have a fix?

9 Reply by Fredjikrang

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

Mine seems to be working again. I let everything cool down, took the front heat sink off of the extruder and cleaned all of the mating surfaces between the heatsinks and the hotend, then assembled it all, tightened the thumb screw and kind of wiggled the hot end a little. I felt it kind of settle into place. Then I started it up again, and it has been printing well since then.

10 Reply by scruffybob (edited by scruffybob 2015-01-29 02:24:46)

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I'm having exactly the same problem.  Set screw is tight, but even with no filament loaded, all I get is the thump, thump, thump when trying to extrude.   I can move the tensioner arm back and I can rotate the stepper wheel by hand, so it's not bound up.

Additionally, when trying to manually retract, I get "random" behavior.    Sometimes it rotates clockwise, sometimes clockwise, sometimes it will go both directions (one after the other).   I've tried adjusting the trimpots as tech support suggests, but they suggested 1.5V for the extruder trimpot and I can't get mine above 1.15v.

Here is a link to my detailed explanation of the problem and what I've found so far:
http://www.soliforum.com/topic/9415/pro … new-press/

11 Reply by Chapin

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

Yep, that is all exactly the same problem I'm running into with my printer. I've checked a lot of the same things you did, and actually used your voltage posts to adjust my extruder's voltage to try to get it to work to no avail. As I said in the other thread (before I saw you replied here), I've got a ticket in with Solidoodle too, but haven't gotten a response yet.

Hopefully this is something that can be fixed relatively soon! This is my first printer and I've gotten just enough out of it to get a taste... I want more!

12 Reply by cbud

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

So I've been doing some research and it looks like this is a problem with other Solidoodle printers, too. I found this video https://www.youtube.com/watch?v=B7_vFWWgo3s - which even though it is a Solidoodle 4 the extruder is making the exact same noise that mine is. In the comments, the user who posted the video said "The problem has been solved. Indeed, it was a loose connection of the motor cable. That's why the engine stopped at one specific location." (thank you, Google Translate).

Additionally, I found this blog http://renaissance-engineer.net/2015/01 … epic-fail/, where the author says that the wires going into the connector get strained and can potentially short.

I'm going to see if direct connecting the wires to the extruder fixes this issue tonight, then I'll look for a less permanent solution if it does - I'll report back my findings.

13 Reply by Chapin (edited by Chapin 2015-01-30 00:29:14)

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

This is a STRONG possibility. I got home and tested the continuity between the ends of the extruder motor cable. Low and behold, one of them was not making continuity. Or rather, it would extremely intermittently as I wiggled the cable a little, as if it wasn't connecting solidly. I'm waiting for my soldering iron to heat up to see if I can solder it for a more solid connection.

Edit 1: So, I got it soldered and put back into the plug and the extruder stepper turns the proper direction at what looks like an appropriate speed, and it sounds good! Buttoning things up to try to actually print!

14 Reply by cbud

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I tested it last night and mine was the wire as well. I opted to remove the connector, cut the wires and just solder them directly to the pins. It's working great now, and I know my solder (and wires) are way more robust than the ones that came with the machine.

15 Reply by cptskippy

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

cbud wrote:

I opted to remove the connector, cut the wires and just solder them directly to the pins.

http://alltheragefaces.com/img/usercrea … 03d212.png

16 Reply by Chapin

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

cptskippy wrote:
cbud wrote:

I opted to remove the connector, cut the wires and just solder them directly to the pins.

http://alltheragefaces.com/img/usercrea … 03d212.png

/agree

I have actual extrusion going on again! I soldered the wire to the connector itself after getting it through. The next problem was that the hot end was clogged up with baked abs. An overnight bath in Acetone helped with that though. Thank you for the help and input throughout the thread!

17 Reply by scruffybob

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I had the exact same problem with the extruder stepper motor going thump, thump, thump.  The wiring had frayed and broke inside the connector to the extruder stepper motor.   Soldering the broken wires fixed my problem the same as you.   Thanks for the pointer.

With the number of us that have already seen this problem, I'd label this a design/manufacturing problem.

http://www.soliforum.com/post/82688/#p82688

18 Reply by matag

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

I am having a similar issue with the Y-Axis Stepper Motor on my Solidoodle Workbench. Even after maxing out the pot on the board, I can't home the Y without helping it, let alone printing anything. If I loosen up the belts, it will work but skips a step every so often. Very unfortunate to not even get a single print out before having issues.

19 Reply by wardjr

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Re: [Solved] Unusual extruder problem... (Extruder Stepper not workinging)

matag wrote:

I am having a similar issue with the Y-Axis Stepper Motor on my Solidoodle Workbench. Even after maxing out the pot on the board, I can't home the Y without helping it, let alone printing anything. If I loosen up the belts, it will work but skips a step every so often. Very unfortunate to not even get a single print out before having issues.

Sounds like you have some binding happening.  There could be many sources of friction but the main thing is alignment of the belts.

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