Thread get's tangled and attached to plate while...

Question

I have been embroidering and sewing on my 180 for 8 years now but within the past 6 months something will happened and thread will get tangled and caught on the plate only when embroidery module is being used. I will hear a metal sort of noise and then it may break a needle or just get all tangled. I will then literally have to cut the hoop away and usually end up ruining another item. It also will usually pull the needle out. I had the machine serviced a few months ago for this problem but it is still doing it. I used to enjoy embroidering but now it's something a dread. Any suggestions? .