fan check hotfix (selftest, measuring RPM, fan errors)

Firmware/Marlin_main.cpp

@@ -8519,8 +8519,13 @@ void setup_fan_interrupt() {
 // and it takes 4.24 us to process (the interrupt invocation overhead not taken into account).
 ISR(INT7_vect) {
 	//measuring speed now works for fanSpeed > 18 (approximately), which is sufficient because MIN_PRINT_FAN_SPEED is higher
-
+#ifdef FAN_SOFT_PWM
+	//if (fanSpeedSoftPwm != 255) return;
+	if ((fanSpeed != 255) || (fanSpeed < MIN_PRINT_FAN_SPEED)) return;
+#else //FAN_SOFT_PWM
 	if (fanSpeed < MIN_PRINT_FAN_SPEED) return;
+#endif //FAN_SOFT_PWM
+
 	if ((1 << 6) & EICRB) { //interrupt was triggered by rising edge
 		t_fan_rising_edge = millis_nc();
 	}
@@ -8887,6 +8892,9 @@ void stop_and_save_print_to_ram(float z_move, float e_move)
 	saved_extruder_under_pressure = extruder_under_pressure; //extruder under pressure flag - currently unused
 	saved_extruder_relative_mode = axis_relative_modes[E_AXIS];
 	saved_fanSpeed = fanSpeed;
+#ifdef FAN_SOFT_PWM
+	if (fan_measuring) saved_fanSpeed = fanSpeedBckp;
+#endif //FAN_SOFT_PWM
 	cmdqueue_reset(); //empty cmdqueue
 	card.sdprinting = false;
 //	card.closefile();

Firmware/planner.cpp

@@ -546,6 +546,7 @@ void check_axes_activity()
   #endif//FAN_KICKSTART_TIME
   #ifdef FAN_SOFT_PWM
   fanSpeedSoftPwm = tail_fan_speed;
+  //printf_P(PSTR("fanspeedsoftPWM %d \n"), fanSpeedSoftPwm);
   #else
   analogWrite(FAN_PIN,tail_fan_speed);
   #endif//!FAN_SOFT_PWM

Firmware/temperature.cpp

@@ -142,7 +142,10 @@ static volatile bool temp_meas_ready = false;
 #if (defined(EXTRUDER_0_AUTO_FAN_PIN) && EXTRUDER_0_AUTO_FAN_PIN > -1) || \
     (defined(EXTRUDER_1_AUTO_FAN_PIN) && EXTRUDER_1_AUTO_FAN_PIN > -1) || \
     (defined(EXTRUDER_2_AUTO_FAN_PIN) && EXTRUDER_2_AUTO_FAN_PIN > -1)
-  static unsigned long extruder_autofan_last_check;
+  unsigned long extruder_autofan_last_check = _millis();
+  uint8_t fanSpeedBckp = 255;
+  bool fan_measuring = false;
+
 #endif  
 
 
@@ -484,6 +487,16 @@ extern bool fans_check_enabled;
 
 void checkFanSpeed()
 {
+	uint8_t max_print_fan_errors = 0;
+	uint8_t max_extruder_fan_errors = 0;
+#ifdef FAN_SOFT_PWM
+	max_print_fan_errors = 3; //15 seconds
+	max_extruder_fan_errors = 2; //10seconds
+#else //FAN_SOFT_PWM
+	max_print_fan_errors = 15; //15 seconds
+	max_extruder_fan_errors = 5; //5 seconds
+#endif //FAN_SOFT_PWM
+
 	fans_check_enabled = (eeprom_read_byte((uint8_t*)EEPROM_FAN_CHECK_ENABLED) > 0);
 	static unsigned char fan_speed_errors[2] = { 0,0 };
 #if (defined(FANCHECK) && defined(TACH_0) && (TACH_0 >-1))
@@ -491,15 +504,15 @@ void checkFanSpeed()
 	else fan_speed_errors[0] = 0;
 #endif
 #if (defined(FANCHECK) && defined(TACH_1) && (TACH_1 >-1))
-	if ((fan_speed[1] == 0) && ((blocks_queued() ? block_buffer[block_buffer_tail].fan_speed : fanSpeed) > MIN_PRINT_FAN_SPEED)) fan_speed_errors[1]++;
+	if ((fan_speed[1] < 5) && ((blocks_queued() ? block_buffer[block_buffer_tail].fan_speed : fanSpeed) > MIN_PRINT_FAN_SPEED)) fan_speed_errors[1]++;
 	else fan_speed_errors[1] = 0;
 #endif
 
-	if ((fan_speed_errors[0] > 5) && fans_check_enabled) {
+	if ((fan_speed_errors[0] > max_extruder_fan_errors) && fans_check_enabled) {
 		fan_speed_errors[0] = 0;
 		fanSpeedError(0); //extruder fan
 	}
-	if ((fan_speed_errors[1] > 15) && fans_check_enabled) {
+	if ((fan_speed_errors[1] > max_print_fan_errors) && fans_check_enabled) {
 		fan_speed_errors[1] = 0;
 		fanSpeedError(1); //print fan
 	}
@@ -734,10 +747,36 @@ void manage_heater()
     #endif
   } // End extruder for loop
 
+#define FAN_CHECK_PERIOD 5000 //5s
+#define FAN_CHECK_DURATION 100 //100ms
+
 #ifndef DEBUG_DISABLE_FANCHECK
   #if (defined(EXTRUDER_0_AUTO_FAN_PIN) && EXTRUDER_0_AUTO_FAN_PIN > -1) || \
       (defined(EXTRUDER_1_AUTO_FAN_PIN) && EXTRUDER_1_AUTO_FAN_PIN > -1) || \
       (defined(EXTRUDER_2_AUTO_FAN_PIN) && EXTRUDER_2_AUTO_FAN_PIN > -1)
+
+#ifdef FAN_SOFT_PWM
+  if ((_millis() - extruder_autofan_last_check > FAN_CHECK_PERIOD) && (!fan_measuring)) {
+	  extruder_autofan_last_check = _millis();
+	  fanSpeedBckp = fanSpeed;
+	  if (fanSpeed > MIN_PRINT_FAN_SPEED) {
+		  fanSpeed = 255;
+	  }
+	 // fanSpeedBckp = fanSpeedSoftPwm;
+	 // fanSpeedSoftPwm = 255;
+	  fan_measuring = true;
+  }
+  if ((_millis() - extruder_autofan_last_check > FAN_CHECK_DURATION) && (fan_measuring)) {
+	  countFanSpeed();
+	  checkFanSpeed();
+	  fanSpeed = fanSpeedBckp;
+	 // fanSpeedSoftPwm = fanSpeedBckp;
+	  printf_P(PSTR("fan PWM: %d; extr fanSpeed measured: %d; print fan speed measured: %d \n"), fanSpeedBckp, fan_speed[0], fan_speed[1]);
+	  extruder_autofan_last_check = _millis();
+	  fan_measuring = false;
+  }
+  checkExtruderAutoFans();
+#else //FAN_SOFT_PWM
   if(_millis() - extruder_autofan_last_check > 1000)  // only need to check fan state very infrequently
   {
 #if (defined(FANCHECK) && ((defined(TACH_0) && (TACH_0 >-1)) || (defined(TACH_1) && (TACH_1 > -1))))
@@ -747,7 +786,9 @@ void manage_heater()
     checkExtruderAutoFans();
     extruder_autofan_last_check = _millis();
   }  
-  #endif       
+#endif //FAN_SOFT_PWM
+
+  #endif  
 #endif //DEBUG_DISABLE_FANCHECK
   
   #ifndef PIDTEMPBED

Firmware/temperature.h

@@ -252,3 +252,7 @@ void check_max_temp();
 
 #endif
 
+extern unsigned long extruder_autofan_last_check;
+extern uint8_t fanSpeedBckp;
+extern bool fan_measuring;
+

Firmware/ultralcd.cpp

@@ -7350,9 +7350,21 @@ static bool lcd_selftest_fan_dialog(int _fan)
 		fanSpeed = 0;
 		manage_heater();			//turn off fan
 		setExtruderAutoFanState(EXTRUDER_0_AUTO_FAN_PIN, 1); //extruder fan
+#ifdef FAN_SOFT_PWM
+		extruder_autofan_last_check = _millis();
+#endif //FAN_SOFT_PWM
 		_delay(2000);				//delay_keep_alive would turn off extruder fan, because temerature is too low
+#ifdef FAN_SOFT_PWM
+		countFanSpeed();
+		if (!fan_speed[0]) _result = false;
+#else //FAN_SOFT_PWM
 		manage_heater();			//count average fan speed from 2s delay and turn off fans
 		if (!fan_speed[0]) _result = false;
+#endif //FAN_SOFT_PWM
+		
+		printf_P(PSTR("Test 1:\n"));
+		printf_P(PSTR("Print fan speed: %d \n"), fan_speed[1]);
+		printf_P(PSTR("Extr fan speed: %d \n"), fan_speed[0]);
 		//SERIAL_ECHOPGM("Extruder fan speed: ");
 		//MYSERIAL.println(fan_speed[0]);
 		//SERIAL_ECHOPGM("Print fan speed: ");
@@ -7361,7 +7373,12 @@ static bool lcd_selftest_fan_dialog(int _fan)
 
 	case 1:
 		//will it work with Thotend > 50 C ?
+#ifdef FAN_SOFT_PWM
+		extruder_autofan_last_check = _millis();
+		fanSpeed = 255;				
+#else //FAN_SOFT_PWM
 		fanSpeed = 150;				//print fan
+#endif //FAN_SOFT_PWM
 		for (uint8_t i = 0; i < 5; i++) {
 			delay_keep_alive(1000);
 			lcd_set_cursor(18, 3);
@@ -7370,15 +7387,26 @@ static bool lcd_selftest_fan_dialog(int _fan)
 			lcd_set_cursor(18, 3);
 			lcd_print("|");
 		}
+#ifdef FAN_SOFT_PWM
+		countFanSpeed();
+		fanSpeed = 0;
+#else //FAN_SOFT_PWM
 		fanSpeed = 0;
 		manage_heater();			//turn off fan
 		manage_inactivity(true);	//to turn off print fan
+#endif //FAN_SOFT_PWM
+		printf_P(PSTR("Test 2:\n"));
+		printf_P(PSTR("Print fan speed: %d \n"), fan_speed[1]);
+		printf_P(PSTR("Extr fan speed: %d \n"), fan_speed[0]);
 		if (!fan_speed[1]) {
 			_result = false; _errno = 6; //print fan not spinning
 		}
+#ifdef FAN_SOFT_PWM 
+		else {
+#else //FAN_SOFT_PWM
 		else if (fan_speed[1] < 34) { //fan is spinning, but measured RPM are too low for print fan, it must be left extruder fan
+#endif //FAN_SOFT_PWM
 			//check fans manually
-
 			_result = lcd_selftest_manual_fan_check(1, true); //turn on print fan and check that left extruder fan is not spinning
 			if (_result) {
 				_result = lcd_selftest_manual_fan_check(1, false); //print fan is stil turned on; check that it is spinning