OpenPnp V2 locks up on my laptop

[Kisssys]

I am trying to get Openpnp V2 with Smoothie Board V1( real deal )to run on my laptop.  I got all the sensors and acutuators up and running and about to finish the vision calibrations and I noticed that if I let it sit for a few minutes and then make a move it will freeze up and not move and Openpnp locks up and won't shut down.  A startup to lockup log included and machine.xml included and my Smoothie Config. Vision is disabled for trouble shooting.

I have to got to open taskmanager to shut down Openpnp.  After doing that I can hook up a terminal program to the smoothie and move it around with Gcode commands so the Smoothie is still working.

I have removed the camera actuators and unplugged both camera's and now have a basic machine that I just jog around and it still locks up after waiting a few minutes.

It' a Dell G16 7630 Win11 and it should handle Openpnp.  

Needs to run on my Laptop so I can move it out of my office. 

Greatly appreciate a little advice on how to fix my problem.

Cheers

Kisssys

[Mike Menci]

Sometimes it takes several minutes to calculate - it was 6-7 min in my case --- did you leave it running - do nothing - just wait --- and than when it pop out window to show details - here is when you need to save the Trace - trace file and send us this one ! 
Please try this 

[Mike Menci]

But this might be the reason why! 

[Kisssys]

I uploaded a log trace in my first post.  For trouble shooting purposes I have removed all camera's so that's not it.  Take a look at the NoCameralockup log.

[Mike Menci]

I wrote ;  - did you leave it running - do nothing - just wait -   and than TRACE-TRACE log (not there in your enclosures) 

[Kisssys]

I started openpnp and turned on PNP machine.  I homed it and then did some jogs to see if I have controll of the axis. I then just left it sit for a while and came back and jogged it again. It moved to that position and then openpnp locked up.  The log attached has of course the time frame.  I was unable to close openpnp so I used task manager to shut it down.  I was able then to start a terminal program and talk to the smoothie board and give it gcode commands and move it around so the smoothie board is working.

I've attached the log, at least I believe it's what you looking for.

I appreciate the help, I'm a hardware guy so bear with me on the code end of this.

Thanks 

Kisssys

[Kisssys]

Maybe your looking for these logs, they're the same I believe.  I view the log while I'm trouble shooting, I just copy to the clipboard and saved them, I did not go to openpnp log page to retrieve them.

These are the logs relative to the time frame I was dealing with from the openpnp log directory.

[Mike Menci]

2025-07-22 10:43:04.969 GcodeDriver$ReaderThread TRACE: [GcodeDriver:COM3] Read error while disconnecting (expected)
Try changing to other USB port on your computer - looks like your COM3 stops responding ...

[Kisssys]

Hmm, I've done that several times.  I've used a usb isolater and not used a isolater.  I know I've connected to Com3-4-5 at different times with the same result on any usb port. The smoothieboard has 2 serial ports and I've used both. I only have one port active on the board at this time but If I turn them both on in config and I see 2 ports and either works.

As an experiment I unplugged the usb cable to see if Openpnp would lock up and it just gives a Com3 port read error but it does not lock up.

The fact that after I let is sit idle for 15 minutes or so and it takes the first jogging command and then locks up seems odd.   Even if it's waiting for the board to send .ok it shouldn't lock up.

No matter what, openpnp shouldn't lock up.

Let me look deeper into a com port error.  I may hook it back up to my main machine and see if it does the same thing, I'll let you know.

Thanks for help!

Kisssys

[Markus Rechberger]

take care that the power wires are separate from the control wires - usb wires must not be routed next to power wires, also shield the communication channel.

It seems like your PNP system has some issues and you better evaluate that problem first. The communication timeout is just the result of the equation.

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[Kisssys]

It worked for several years on V1 it's been going to Openpnp v2 that has been frustrating.  Good advice though.  

[Rambo Jon]

Did it work for you?

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[Mike Menci]

Are you  using a USB Hub ?

[Kisssys]

I have but I'm not using one now to isolate the problem.  

In this line you posted.

2025-07-22 10:43:04.969 GcodeDriver$ReaderThread TRACE: [GcodeDriver:COM3] Read error while disconnecting (expected)
Try changing to other USB port on your computer - looks like your COM3 stops responding ...

It looks like openpnp elected to shut it down, it didn't fail. I doubt if it's the port failing. Maybe something to do with M400 lack of response.

 I've changed 2 things, the smoothieware firmware and openpnp v1 to v2.  

I had to change the smoothieboard because of not addressing the nozzles as extruders but A and B.  Maybe someone has a smoothieboard firmware that is working well with v2

[Nikolay Alekseev]

I have often encountered problems with WinUSB and USB-CDC devices when working on laptops with a built-in card reader. I recommend disabling the card reader in the device manager.

ср, 23 июл. 2025 г., 15:33 Kisssys <kisy...@gmail.com>:

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[Kisssys]

Ok, my laptop does not have a built in card reader oddly enough I have to attach an external one to a usb port.  I was dissappointed when I got the laptop but oh well.  I did look in the device manager and did not see one.

 

I have put the same machine xml on both my laptop and the computer I used to run it on both with the same openpnp version.  It fails the same.

This is just a simple cnc machine, no camera's.  I left all the actuator  definitions but removed the camera ones for trouble shooting.

Does the same on both computers.

[Mike Menci]

Try cameras with AMCap if they work fellowly ,.... 

[Kisssys]

Read the first post, camera's have nothing to do with it.

[Jason von Nieda]

Howdy Kisssys,

Sounds like you've ruled out pretty much everything. I agree - OpenPnP should not just be locking up regardless. Here's the only things I can think of:

1. I've heard more reports related to USB suspend / sleep since Windows 11 came out. I personally have no experience, but I lurk in a lot of embedded spaces and I've seen it coming up. May be worth checking: https://www.elevenforum.com/t/enable-or-disable-usb-selective-suspend-in-windows-11.10251/
2. Are you running Mark's Smoothie firmware? If not, look in the Issues and Solutions and see if there is something there about updating. I don't know that it would cause a lockup, but I know it's the recommended firmware.
3. The next time it happens, and you use Task Manager to kill it, see if it's showing a lot of CPU usage or RAM usage. That would give a hint. 

Jason

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[Kisssys]

Yep getting frustrated.  I'll look at the usb suspend issue.  I do have a WIN10 machine, I guess I should try it also.

I found this smoothie firmware somewhere a year ago and am clueless as to where it came from.  I am not familiar with Mark's firmware but would appreciate a link and I'll try it.

In Task Manager I've seen the memory start out at about 230 and end up at 440 and it's basically doing nothing.  But it has locked up long before it gets over 250.

I'm looking for something like printrun for win 11 so I can create a gcode file and exercise the machine without using openpnp.

My gut feel it's the Smoothie firmware but when I get a lockup, I can shut down openpnp, go to my terminal program and move it around with no issures

I've tried to send it to G01 Y150 F300 and I receive OK I then send a M400 and when it stops I get an OK

I tried running without any logging and it does the same thing.

I've got a spare CO2 tube and I'm about to tare it apart.  I've build a dozen different types of cnc machines but this was the most challenging, I hate to give up

Cheers

Kisssys

[Kisssys]

I was sure that USB suspend was the problem but I've turned it off on my win11 tower and my laptop with no change.  Dissapointed.  I ordered a USB2 powered hub to put between the PC and openpnp to see if I can trick

it to stay working.

Good news is it works fine back on Windows 10.  Going thru all the chatgpt suggestions to cure the problem,  its a long list.  

May go to Linux but I worry about the camera setup. 

Cheers Kisssys

[ThePoll100]

Hello, I have the same problem with Windows 11 and a Dell laptop. In Windows 10 everything works, in Windows 11 at random intervals there is a loss of communication with the motherboard and an M400 error. After restarting the program, it works. I don't have to restart the motherboard. I've tried everything. The program versions are identical on Win 10 and Win 11. Any ideas?

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[Vinay Dand]

Kisssys,

IMHO you need to use Mark's Firmware for the Smoothieware.
https://github.com/openpnp/openpnp/wiki/Motion-Controller-Firmwares

Download link is there under Smoothieware Topic

Also take a look at
https://github.com/openpnp/openpnp/wiki/Motion-Controllers

Regards,
Vinay

[Kisssys]

That is the current firmware I'm using for 5 axis.  Tried 6 axis also does the same. Thanks for commenting.

This is what I've done the last 2 days.

I tried to use TCP telnet and it worked and seemed to be reliable but it is too slow to be practical.  It takes 400ms to send back an .ok response.

It locks up on 2 WIN11 computers and a new Ubuntu installaton.

Tried 3 different usb cables with isolator.

Changed the processor LPC1769 on my Smoothie board with no change.

What does appear to bypass the USB problem  on the Smoothie is to connect to uart0 with a FTDI cable ( update to new win11 drivers ).  I'm communicating at 500k so it would slow things down a little I guess. Both the LPC1769 and a
real FTDI cable can go much faster.

I did this in my Smoothie config.

# Serial communications configuration ( baud rate default to 9600 if undefined )

panel. Enable                                  false
uart0.baud_rate                                500000             # Baud rate for the default hardware serial port
second_usb_serial_enable                       true               # This enables a second usb serial port (to have both pronterface and a terminal connected)
msd_disable                                    true               # disable the MSD (USB SDCARD) when set to true

The panel setting and the msd_disable are just shots in the dark.

This is still in testing so no promises but I've had it run for 4 hours today with no lockups and the memory usage seems stable.

When it locks up and I can't shut down openpnp I go to task manager and I can see that openpnp is still doing something using a few percent of cpu power.  I unplugged the camera's that goes to zero.

I might note that if I give it a large gcode file with pronterface, it runs the file until it's finished.  Seems like if you keep it busy it keeps working.

Openpnp should never lock up.  It has done it on 2 WIN11's and a Ubuntu install.

Cheers

Kisssys

[ThePoll100]

Hey, I checked today on another Windows 11 computer and it's the same. It works fine on two Windows 10 computers. What other drivers are there? I found two, but they turned out to be the same. Regards 

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[Kisssys]

I hope you find one that works.  Using a FTDI 3V3 cable to the Uart0 port on my SmoothieboardV1 seems very stable.   You need to not turn on rts/cts as the uart0 on the SmoothieboardV1 does not have them connected. Actually

any board that uses the usb input directly to the microprocessor turning on flow control shouldn't do anything anyway.  I pulled the 5V pin out of the cable and taped it back, their are jumpers on the board that could accidently wire that to 3v3 volts

although mine has the jumpers to 5v so it shouldn't of mattered.  I'm sure their will always be a good driver for an external USB to serial port and should be a long term answer for my SmoothieV1.  You do lose the ability to edit you config file without popping out the sd card. 

Good Luck.

[ThePoll100]

Hey, does anything need to be changed in the program configuration besides the port number?

How to connect ftdi port exactly? Regards

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[Kisssys]

Find the uart0 just to the right of the red play button.  The pins are marked with ground to the left toward the red play button.  They are correct for a true FTDI 3v3 cable.  As I mentioned I would make sure the 5 volt pin is hooked to the 5volt

buss on the smoothie board with the solder jumper on the back of the board.   Or it's just as easy to pull out the +5volt wire out of the FTDI connector to be safe.  Use a 3v3 volt logic level cable, I'm not sure of the LPC1769 tolerance of 5v signals. RTS and CTS are not connected to the processor on my board.  The TX RX and GND are the only pins used.

tx to rx rx to tx.  In the Smoothie config file do as I suggested in a previous post.  Just choose the port the FTDI cable enumerates and set the speed to match the config file setting. I used 500k.  Don't chose flow control. 

Note, any usb to ttl converter should work and their are a lot of clones of the FTDI cables.  Sparkfun for one.  Some clones I've seen have a different pinout and some don't have the same flow control pins.  Get TX RX and GND you

should be ok.  Their are WIN11 FTDI drivers on their website.

Cheers

Kisssys

[Kisssys]

I forgot to mention, unplug the usb connector on the Smoothiev1

[ThePoll100]

Thanks for the tip, I connected it and it works 😃

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