[SKR PRO 1.1/TMC5160] Motors randomly stop working until power cycle

Hello,

I am having an issue with my homemade core xy, running an SKR 1.1 PRO with TMC5160 drivers.
I am using the marlin 2.x branch, commit 1d631b72801174b29e2d5cb2115022a194ed303b from November 21st

Everything works fine until a motor stops working. I enabled TMC debugging but I don't see anything odd.

Some logs when I noticed the print going wrong (the print head is only moving in diagonal because the 2d motor, usually Y, doesn't rotate anymore)

X:91/28/0|T|	Y:121/28/0|T|	Z:24/12/-|GTI|	Z2:21/12/-|GTI|	Z3:25/12/-|GTI|	E:48/19/0|T|
X:85/28/0|T|	Y:118/28/0|T|	Z:24/12/-|GTI|	Z2:26/12/-|GTI|	Z3:24/12/-|GTI|	E:48/19/0|T|
X:107/28/0|T|	Y:164/28/0|T|	Z:24/12/-|GTI|	Z2:22/12/-|GTI|	Z3:25/12/-|GTI|	E:49/19/0|T|
X:103/28/0|T|	Y:153/28/0|T|	Z:24/12/-|GTI|	Z2:24/12/-|GTI|	Z3:26/12/-|GTI|	E:49/19/0|T|
X:107/28/0|T|	Y:159/28/0|T|	Z:24/12/-|GTI|	Z2:21/12/-|GTI|	Z3:25/12/-|GTI|	E:49/19/0|T|
X:165/28/0|T|	Y:125/28/0|T|	Z:24/12/-|GTI|	Z2:26/12/-|GTI|	Z3:25/12/-|GTI|	E:49/19/0|T|
X:84/28/0|T|	Y:93/28/0|T|	Z:25/12/-|GTI|	Z2:22/12/-|GTI|	Z3:25/12/-|GTI|	E:48/19/0|T|

I stopped the print, and tried to home from the screen and got an error :


I pressed the screen reset button.

Here is a M122 output after the reset :

Printer is now online.
>>> M122
SENDING:M122
axis:pwm_scale/curr_scale/mech_load|flags|warncount
		X	Y	Z	Z2	Z3	E
Enabled		false	false	false	false	false	false
Set current	1400	1400	1200	1200	1200	1000
RMS current	1395	1395	1188	1188	1188	990
MAX current	1967	1967	1675	1675	1675	1396
Run current	28/31	28/31	24/31	24/31	24/31	19/31
Hold current	14/31	14/31	12/31	12/31	12/31	9/31
Global scaler	129/256	129/256	128/256	128/256	128/256	133/256
CS actual	14/31	14/31	12/31	12/31	12/31	9/31
PWM scale	786485	44	23	21	131097	24
stealthChop	true	true	true	true	true	true
msteps		16	16	16	16	16	16
tstep		max	max	max	max	max	max
PWM thresh.	98	98	658	658	658	59
[mm/s]		100	100	3	3	3	30
OT prewarn	false	false	false	false	false	false
triggered
 OTP		false	false	false	false	false	false
off time	4	4	4	4	4	4
blank time	24	24	24	24	24	24
hysteresis
 -end		2	2	2	2	2	2
 -start		1	1	1	1	1	1
Stallguard thrs	0	0	0	0	0	0
uStep count	872	728	216	536	312	856
DRVSTATUS	X	Y	Z	Z2	Z3	E
sg_result	0	0	0	0	0	0
stallguard			*	*	*
fsactive
stst
olb
ola
s2gb
s2ga
otpw
ot
Driver registers:
		X	0x80:0E:40:00
		Y	0x80:0E:40:00
		Z	0x81:0C:40:00
		Z2	0x81:0C:40:00
		Z3	0x81:0C:40:00
		E	0x80:09:40:00
Testing X connection... OK
Testing Y connection... OK
Testing Z connection... OK
Testing Z2 connection... OK
Testing Z3 connection... OK
Testing E connection... OK

Then I tried to home X from pronterface, the printer moves on Z, but not on X/Y, then crashes

X:53/14/-|TI|	Y:44/14/-|TI|	Z:23/12/-|GTI|	Z2:24/12/-|GTI|	Z3:24/12/-|GTI|	E:24/9/-|TI|
X:53/14/-|TI|	Y:44/14/-|TI|	Z:47/24/0|G|	Z2:45/24/0|G|	Z3:49/24/0|G|	E:24/9/-|TI|
X:53/14/-|TI|	Y:44/14/-|TI|	Z:47/24/0|G|	Z2:45/24/0|G|	Z3:49/24/0|G|	E:24/9/-|TI|
X:143/28/0|T|	Y:135/28/0|T|	Z:46/24/-|GTI|	Z2:42/24/-|GTI|	Z3:45/24/-|GTI|	E:24/9/-|TI|
echo:busy: processing
X:143/28/0|T|	Y:136/28/0|T|	Z:46/24/-|GTI|	Z2:40/24/-|GTI|	Z3:45/24/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:44/24/-|GTI|	Z2:41/24/-|GTI|	Z3:45/24/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:42/24/-|GTI|	Z2:42/24/-|GTI|	Z3:45/24/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:43/24/-|GTI|	Z2:42/24/-|GTI|	Z3:45/24/-|GTI|	E:24/9/-|TI|
echo:busy: processing
X:143/28/0|T|	Y:136/28/0|T|	Z:42/24/-|GTI|	Z2:42/24/-|GTI|	Z3:46/24/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:43/23/-|GTI|	Z2:39/23/-|GTI|	Z3:44/23/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:38/21/-|GTI|	Z2:37/21/-|GTI|	Z3:41/21/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:34/18/-|GTI|	Z2:31/18/-|GTI|	Z3:34/18/-|GTI|	E:24/9/-|TI|
echo:busy: processing
X:143/28/0|T|	Y:135/28/0|T|	Z:29/16/-|GTI|	Z2:29/16/-|GTI|	Z3:30/16/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:29/14/-|GTI|	Z2:24/14/-|GTI|	Z3:28/14/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:23/12/-|GTI|	Z2:25/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:23/12/-|GTI|	Z2:26/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
echo:busy: processing
X:143/28/0|T|	Y:136/28/0|T|	Z:24/12/-|GTI|	Z2:25/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:23/12/-|GTI|	Z2:21/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:24/12/-|GTI|	Z2:26/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
X:143/28/0|T|	Y:136/28/0|T|	Z:23/12/-|GTI|	Z2:24/12/-|GTI|	Z3:25/12/-|GTI|	E:24/9/-|TI|
Errorrinter halted. kill() called!
[ERROR] Errorrinter halted. kill() called!

So a soft reset doesn't seem to bring back the drivers/motors, but if I power off for 5s then power on, the motors are working fine and I can home without any issue.

I am not sure if this is a software or hardware issue, but I am hoping that someone will be able to help me on this !

Edited 1 time(s). Last edit at 12/04/2020 05:43AM by munchj.

The I flag is standstill, and you can see that the stepper drivers think they are moving...

See [github.com] for flags

Marlin will halt if it attempts to home and it moves greater than bed size without hitting an endstops (eg if it didn't actually move)

Cant provide any further incite...

I just ran the exact same G-CODE and the printer failed in the same fashion, which could mean it is not so random and probably a software issue.



I attached the G-CODE file and I am going to try to find out exactly after which command the printer fails

Hi,

so I did some changes in my marlin configuration and I think I might have fixed the issue.

So far I did not experience the issue since this change:
- disabled the HYBRID TRESHOLD (in the print i was doing, speed was 60mm/s and travel at 150mm/s, the treshold beeing at 100mm/s, it was probably switching modes back and forth several times quickly)
- reduced x/y current from 1400 to 1200mA

I'll report back if I experience the issue again