MAKER FAIRE

filament sensor: runout detection tuning, save/restore print
silent mode: safe mode selection durring printing and after homing

Firmware/Marlin_main.cpp

@@ -565,27 +565,45 @@ void servo_init()
 
 static void lcd_language_menu();
 
+void stop_and_save_print_to_ram(float z_move, float e_move);
+void restore_print_from_ram_and_continue(float e_move);
+
 
 #ifdef PAT9125
 
+void fsensor_stop_and_save_print()
+{
+//	stop_and_save_print_to_ram(10, -0.8); //XY - no change, Z 10mm up, E 0.8mm in
+	stop_and_save_print_to_ram(0, 0); //XY - no change, Z 10mm up, E 0.8mm in
+}
+
+void fsensor_restore_print_and_continue()
+{
+	restore_print_from_ram_and_continue(0); //XYZ = orig, E - no change
+}
+
+
 bool fsensor_enabled = true;
 bool fsensor_ignore_error = true;
 bool fsensor_M600 = false;
-long prev_pos_e = 0;
-long err_cnt = 0;
+long fsensor_prev_pos_e = 0;
+uint8_t fsensor_err_cnt = 0;
 
 #define FSENS_ESTEPS 280  //extruder resolution [steps/mm]
-#define FSENS_MINDEL 560  //filament sensor min delta [steps] (3mm)
+//#define FSENS_MINDEL 560  //filament sensor min delta [steps] (3mm)
+#define FSENS_MINDEL 280  //filament sensor min delta [steps] (3mm)
 #define FSENS_MINFAC 3    //filament sensor minimum factor [count/mm]
-#define FSENS_MAXFAC 50   //filament sensor maximum factor [count/mm]
-#define FSENS_MAXERR 2    //filament sensor max error count
+//#define FSENS_MAXFAC 50   //filament sensor maximum factor [count/mm]
+#define FSENS_MAXFAC 40   //filament sensor maximum factor [count/mm]
+//#define FSENS_MAXERR 2    //filament sensor max error count
+#define FSENS_MAXERR 5    //filament sensor max error count
 
 void fsensor_enable()
 {
 	MYSERIAL.println("fsensor_enable");
 	pat9125_y = 0;
-	prev_pos_e = st_get_position(E_AXIS);
-	err_cnt = 0;
+	fsensor_prev_pos_e = st_get_position(E_AXIS);
+	fsensor_err_cnt = 0;
 	fsensor_enabled = true;
 	fsensor_ignore_error = true;
 	fsensor_M600 = false;
@@ -602,24 +620,26 @@ void fsensor_update()
 	if (!fsensor_enabled) return;
 	long pos_e = st_get_position(E_AXIS); //current position
 	pat9125_update();
-	long del_e = pos_e - prev_pos_e; //delta
+	long del_e = pos_e - fsensor_prev_pos_e; //delta
 	if (abs(del_e) < FSENS_MINDEL) return;
 	float de = ((float)del_e / FSENS_ESTEPS);
 	int cmin = de * FSENS_MINFAC;
 	int cmax = de * FSENS_MAXFAC;
-	int cnt = pat9125_y;
-	prev_pos_e = pos_e;
+	int cnt = -pat9125_y;
+	fsensor_prev_pos_e = pos_e;
 	pat9125_y = 0;
 	bool err = false;
 	if ((del_e > 0) && ((cnt < cmin) || (cnt > cmax))) err = true;
 	if ((del_e < 0) && ((cnt > cmin) || (cnt < cmax))) err = true;
 	if (err)
-		err_cnt++;
+		fsensor_err_cnt++;
 	else
-		err_cnt = 0;
+		fsensor_err_cnt = 0;
 
 /**/
-	MYSERIAL.print("de=");
+	MYSERIAL.print("pos_e=");
+	MYSERIAL.print(pos_e);
+	MYSERIAL.print(" de=");
 	MYSERIAL.print(de);
 	MYSERIAL.print(" cmin=");
 	MYSERIAL.print((int)cmin);
@@ -628,13 +648,13 @@ void fsensor_update()
 	MYSERIAL.print(" cnt=");
 	MYSERIAL.print((int)cnt);
 	MYSERIAL.print(" err=");
-	MYSERIAL.println((int)err_cnt);/**/
+	MYSERIAL.println((int)fsensor_err_cnt);/**/
 
-	return;
+//	return;
 
-	if (err_cnt > FSENS_MAXERR)
+	if (fsensor_err_cnt > FSENS_MAXERR)
 	{
-		MYSERIAL.println("fsensor_update (err_cnt > FSENS_MAXERR)");
+		MYSERIAL.println("fsensor_update (fsensor_err_cnt > FSENS_MAXERR)");
 		if (fsensor_ignore_error)
 		{
 			MYSERIAL.println("fsensor_update - error ignored)");
@@ -643,10 +663,10 @@ void fsensor_update()
 		else
 		{
 			MYSERIAL.println("fsensor_update - ERROR!!!");
-			planner_abort_hard();
-//			enquecommand_front_P((PSTR("M600")));
-//			fsensor_M600 = true;
-//			fsensor_enabled = false;
+			fsensor_stop_and_save_print();
+			enquecommand_front_P((PSTR("M600")));
+			fsensor_M600 = true;
+			fsensor_enabled = false;
 		}
 	}
 }
@@ -5233,7 +5253,14 @@ case 404:  //M404 Enter the nominal filament width (3mm, 1.75mm ) N<3.0> or disp
 	  if (fsensor_M600)
 	  {
 		cmdqueue_pop_front(); //hack because M600 repeated 2x when enqueued to front
+		st_synchronize();
+		while (!is_buffer_empty())
+		{
+			process_commands();
+		    cmdqueue_pop_front();
+		}
 		fsensor_enable();
+		fsensor_restore_print_and_continue();
 	  }
 #endif //PAT9125
         
@@ -6898,50 +6925,49 @@ float saved_feedrate2 = 0;
 uint8_t saved_active_extruder = 0;
 bool saved_extruder_under_pressure = false;
 
-
-void stop_and_save_print_to_ram()
+void stop_and_save_print_to_ram(float z_move, float e_move)
 {
 	if (saved_printing) return;
 	cli();
-	saved_sdpos = sdpos_atomic;
-	uint16_t sdlen_planner = planner_calc_sd_length();
+	saved_sdpos = sdpos_atomic; //atomic sd position of last command added in queue
+	uint16_t sdlen_planner = planner_calc_sd_length(); //length of sd commands in planner
 	saved_sdpos -= sdlen_planner;
-	uint16_t sdlen_cmdqueue = cmdqueue_calc_sd_length();
+	uint16_t sdlen_cmdqueue = cmdqueue_calc_sd_length(); //length of sd commands in cmdqueue
 	saved_sdpos -= sdlen_cmdqueue;
-	planner_abort_hard();
-//	babystep_reset();
-	for (int axis = X_AXIS; axis <= E_AXIS; axis++)
+	planner_abort_hard(); //abort printing
+	for (int axis = X_AXIS; axis <= E_AXIS; axis++) //save positions
 		saved_pos[axis] = current_position[axis];
-	saved_feedrate2 = feedrate;
-	saved_active_extruder = active_extruder;
-	saved_extruder_under_pressure = extruder_under_pressure;
-	cmdqueue_reset();
+//		saved_pos[axis] = st_get_position_mm(axis);
+	saved_feedrate2 = feedrate; //save feedrate
+	saved_active_extruder = active_extruder; //save active_extruder
+
+	saved_extruder_under_pressure = extruder_under_pressure; //extruder under pressure flag - currently unused
+
+	cmdqueue_reset(); //empty cmdqueue
 	card.sdprinting = false;
 //	card.closefile();
 	saved_printing = true;
 	sei();
-	float extruder_move = 0;
-	if (extruder_under_pressure) extruder_move -= 0.8;
-	plan_buffer_line(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS] + 10, current_position[E_AXIS] + extruder_move, homing_feedrate[Z_AXIS], active_extruder);
-    st_synchronize();
+	if ((z_move != 0) || (e_move != 0)) // extruder and z move
+		plan_buffer_line(saved_pos[X_AXIS], saved_pos[Y_AXIS], saved_pos[Z_AXIS] + z_move, saved_pos[E_AXIS] + e_move, homing_feedrate[Z_AXIS], active_extruder);
+    st_synchronize(); //wait moving
 	MYSERIAL.print("SDPOS="); MYSERIAL.println(sdpos_atomic, DEC);
 	MYSERIAL.print("SDLEN_PLAN="); MYSERIAL.println(sdlen_planner, DEC);
 	MYSERIAL.print("SDLEN_CMDQ="); MYSERIAL.println(sdlen_cmdqueue, DEC);
 
 }
 
-void restore_print_from_ram_and_continue()
+void restore_print_from_ram_and_continue(float e_move)
 {
 	if (!saved_printing) return;
-//	babystep_apply();
-	for (int axis = X_AXIS; axis <= E_AXIS; axis++)
-	    current_position[axis] = st_get_position_mm(axis);
-	active_extruder = saved_active_extruder;
-	float extruder_move = 0;
-	if (saved_extruder_under_pressure) extruder_move += 0.8;
-	plan_buffer_line(saved_pos[X_AXIS], saved_pos[Y_AXIS], saved_pos[Z_AXIS], current_position[E_AXIS] + extruder_move, homing_feedrate[Z_AXIS], active_extruder);
+//	for (int axis = X_AXIS; axis <= E_AXIS; axis++)
+//	    current_position[axis] = st_get_position_mm(axis);
+	active_extruder = saved_active_extruder; //restore active_extruder
+	feedrate = saved_feedrate2; //restore feedrate
+	float e = saved_pos[E_AXIS] - e_move;
+	plan_set_e_position(e);
+	plan_buffer_line(saved_pos[X_AXIS], saved_pos[Y_AXIS], saved_pos[Z_AXIS], saved_pos[E_AXIS], homing_feedrate[Z_AXIS], active_extruder);
     st_synchronize();
-	feedrate = saved_feedrate2;
 	card.setIndex(saved_sdpos);
 	card.sdprinting = true;
 	saved_printing = false;

Firmware/language_all.cpp

@@ -2863,12 +2863,12 @@ const char * const MSG_SHOW_END_STOPS_LANG_TABLE[LANG_NUM] PROGMEM = {
 	MSG_SHOW_END_STOPS_DE
 };
 
-const char MSG_FSENSOR_OFF_EN[] PROGMEM = "Filam. probe [off]";
-const char MSG_FSENSOR_OFF_CZ[] PROGMEM = "Filam. probe [off]";
-const char MSG_FSENSOR_OFF_IT[] PROGMEM = "Filam. probe [off]";
-const char MSG_FSENSOR_OFF_ES[] PROGMEM = "Filam. probe [off]";
-const char MSG_FSENSOR_OFF_PL[] PROGMEM = "Filam. probe [off]";
-const char MSG_FSENSOR_OFF_DE[] PROGMEM = "Filam. probe [off]";
+const char MSG_FSENSOR_OFF_EN[] PROGMEM = "Fil. sensor [off]";
+const char MSG_FSENSOR_OFF_CZ[] PROGMEM = "Fil. sensor [off]";
+const char MSG_FSENSOR_OFF_IT[] PROGMEM = "Fil. sensor [off]";
+const char MSG_FSENSOR_OFF_ES[] PROGMEM = "Fil. sensor [off]";
+const char MSG_FSENSOR_OFF_PL[] PROGMEM = "Fil. sensor [off]";
+const char MSG_FSENSOR_OFF_DE[] PROGMEM = "Fil. sensor [off]";
 const char * const MSG_FSENSOR_OFF_LANG_TABLE[LANG_NUM] PROGMEM = {
 	MSG_FSENSOR_OFF_EN,
 	MSG_FSENSOR_OFF_CZ,
@@ -2878,12 +2878,12 @@ const char * const MSG_FSENSOR_OFF_LANG_TABLE[LANG_NUM] PROGMEM = {
 	MSG_FSENSOR_OFF_DE
 };
 
-const char MSG_FSENSOR_ON_EN[] PROGMEM = "Filam. probe  [on]";
-const char MSG_FSENSOR_ON_CZ[] PROGMEM = "Filam. probe  [on]";
-const char MSG_FSENSOR_ON_IT[] PROGMEM = "Filam. probe  [on]";
-const char MSG_FSENSOR_ON_ES[] PROGMEM = "Filam. probe  [on]";
-const char MSG_FSENSOR_ON_PL[] PROGMEM = "Filam. probe  [on]";
-const char MSG_FSENSOR_ON_DE[] PROGMEM = "Filam. probe  [on]";
+const char MSG_FSENSOR_ON_EN[] PROGMEM = "Fil. sensor  [on]";
+const char MSG_FSENSOR_ON_CZ[] PROGMEM = "Fil. sensor  [on]";
+const char MSG_FSENSOR_ON_IT[] PROGMEM = "Fil. sensor  [on]";
+const char MSG_FSENSOR_ON_ES[] PROGMEM = "Fil. sensor  [on]";
+const char MSG_FSENSOR_ON_PL[] PROGMEM = "Fil. sensor  [on]";
+const char MSG_FSENSOR_ON_DE[] PROGMEM = "Fil. sensor  [on]";
 const char * const MSG_FSENSOR_ON_LANG_TABLE[LANG_NUM] PROGMEM = {
 	MSG_FSENSOR_ON_EN,
 	MSG_FSENSOR_ON_CZ,

Firmware/stepper.cpp

@@ -36,6 +36,9 @@
 #include "tmc2130.h"
 #endif //TMC2130
 
+#ifdef PAT9125
+extern uint8_t fsensor_err_cnt;
+#endif //PAT9125
 
 //===========================================================================
 //=============================public variables  ============================
@@ -759,6 +762,12 @@ void isr() {
 
     // If current block is finished, reset pointer
     if (step_events_completed >= current_block->step_event_count) {
+
+#ifdef PAT9125
+		if (current_block->steps_e < 0) //black magic - decrement filament sensor errors for negative extruder move
+			if (fsensor_err_cnt) fsensor_err_cnt--;
+#endif //PAT9125
+
       current_block = NULL;
       plan_discard_current_block();
     }

Firmware/tmc2130.cpp

@@ -277,13 +277,19 @@ void tmc2130_home_exit()
 			if (sg_homing_axes_mask & mask & (X_AXIS_MASK | Y_AXIS_MASK))
 			{
 				if (tmc2130_mode == TMC2130_MODE_SILENT)
+				{
 					tmc2130_wr(tmc2130_cs[axis], TMC2130_REG_GCONF, TMC2130_GCONF_SILENT); // Configuration back to stealthChop
+					tmc2130_wr(tmc2130_cs[axis], TMC2130_REG_TCOOLTHRS, 0);
+//					tmc2130_wr_PWMCONF(tmc2130_cs[i], tmc2130_pwm_ampl[i], tmc2130_pwm_grad[i], tmc2130_pwm_freq[i], tmc2130_pwm_auto[i], 0, 0);
+				}
 				else
+				{
 #ifdef TMC2130_SG_HOMING_SW_XY
 					tmc2130_wr(tmc2130_cs[axis], TMC2130_REG_GCONF, TMC2130_GCONF_NORMAL);
 #else //TMC2130_SG_HOMING_SW_XY
 					tmc2130_wr(tmc2130_cs[axis], TMC2130_REG_GCONF, TMC2130_GCONF_SGSENS);
 #endif //TMC2130_SG_HOMING_SW_XY
+				}
 			}
 			tmc2130_axis_stalled[axis] = false;
 		}

Firmware/ultralcd.cpp

@@ -971,17 +971,17 @@ static void lcd_menu_temperatures()
     }
 }
 
-extern void stop_and_save_print_to_ram();
-extern void restore_print_from_ram_and_continue();
+extern void stop_and_save_print_to_ram(float z_move, float e_move);
+extern void restore_print_from_ram_and_continue(float e_move);
 
 static void lcd_menu_test_save()
 {
-	stop_and_save_print_to_ram();
+	stop_and_save_print_to_ram(10, -0.8);
 }
 
 static void lcd_menu_test_restore()
 {
-	restore_print_from_ram_and_continue();
+	restore_print_from_ram_and_continue(0.8);
 }
 
 static void lcd_preheat_menu()
@@ -2523,8 +2523,11 @@ static void lcd_silent_mode_set() {
   SilentModeMenu = !SilentModeMenu;
   eeprom_update_byte((unsigned char *)EEPROM_SILENT, SilentModeMenu);
 #ifdef TMC2130
+  st_synchronize();
+  cli();
 	tmc2130_mode = SilentModeMenu?TMC2130_MODE_SILENT:TMC2130_MODE_NORMAL;
 	tmc2130_init();
+  sei();
 #endif //TMC2130
   digipot_init();
   lcd_goto_menu(lcd_settings_menu, 7);
@@ -3987,8 +3990,11 @@ static void lcd_silent_mode_set_tune() {
   SilentModeMenu = !SilentModeMenu;
   eeprom_update_byte((unsigned char*)EEPROM_SILENT, SilentModeMenu);
 #ifdef TMC2130
+  st_synchronize();
+  cli();
 	tmc2130_mode = SilentModeMenu?TMC2130_MODE_SILENT:TMC2130_MODE_NORMAL;
 	tmc2130_init();
+  sei();
 #endif //TMC2130
   digipot_init();
   lcd_goto_menu(lcd_tune_menu, 9);