#include #include #include "io_atmega2560.h" // All this is about silencing the heat bed, as it behaves like a loudspeaker. // Basically, we want the PWM heating switched at 30Hz (or so) which is a well ballanced // frequency for both power supply units (i.e. both PSUs are reasonably silent). // The only trouble is the rising or falling edge of bed heating - that creates an audible click. // This audible click may be suppressed by making the rising or falling edge NOT sharp. // Of course, making non-sharp edges in digital technology is not easy, but there is a solution. // It is possible to do a fast PWM sequence with duty starting from 0 to 255. // Doing this at higher frequency than the bed "loudspeaker" can handle makes the click barely audible. // Technically: // timer0 is set to fast PWM mode at 62.5kHz (timer0 is linked to the bed heating pin) (zero prescaler) // To keep the bed switching at 30Hz - we don't want the PWM running at 62kHz all the time // since it would burn the heatbed's MOSFET: // 16MHz/256 levels of PWM duty gives us 62.5kHz // 62.5kHz/256 gives ~244Hz, that is still too fast - 244/8 gives ~30Hz, that's what we need // So the automaton runs atop of inner 8 (or 16) cycles. // The finite automaton is running in the ISR(TIMER0_OVF_vect) // 2019-08-14 update: the original algorithm worked very well, however there were 2 regressions: // 1. 62kHz ISR requires considerable amount of processing power, // USB transfer speed dropped by 20%, which was most notable when doing short G-code segments. // 2. Some users reported TLed PSU started clicking when running at 120V/60Hz. // This looks like the original algorithm didn't maintain base PWM 30Hz, but only 15Hz // To address both issues, there is an improved approach based on the idea of leveraging // different CLK prescalers in some automaton states - i.e. when holding LOW or HIGH on the output pin, // we don't have to clock 62kHz, but we can increase the CLK prescaler for these states to 8 (or even 64). // That shall result in the ISR not being called that much resulting in regained performance // Theoretically this is relatively easy, however one must be very carefull handling the AVR's timer // control registers correctly, especially setting them in a correct order. // Some registers are double buffered, some changes are applied in next cycles etc. // The biggest problem was with the CLK prescaler itself - this circuit is shared among almost all timers, // we don't want to reset the prescaler counted value when transiting among automaton states. // Resetting the prescaler would make the PWM more precise, right now there are temporal segments // of variable period ranging from 0 to 7 62kHz ticks - that's logical, the timer must "sync" // to the new slower CLK after setting the slower prescaler value. // In our application, this isn't any significant problem and may be ignored. // Doing changes in timer's registers non-correctly results in artefacts on the output pin // - it can toggle unnoticed, which will result in bed clicking again. // That's why there are special transition states ZERO_TO_RISE and ONE_TO_FALL, which enable the // counter change its operation atomically and without artefacts on the output pin. // The resulting signal on the output pin was checked with an osciloscope. // If there are any change requirements in the future, the signal must be checked with an osciloscope again, // ad-hoc changes may completely screw things up! ///! Definition off finite automaton states enum class States : uint8_t { ZERO_START = 0,///< entry point of the automaton - reads the soft_pwm_bed value for the next whole PWM cycle ZERO, ///< steady 0 (OFF), no change for the whole period ZERO_TO_RISE, ///< metastate allowing the timer change its state atomically without artefacts on the output pin RISE, ///< 16 fast PWM cycles with increasing duty up to steady ON RISE_TO_ONE, ///< metastate allowing the timer change its state atomically without artefacts on the output pin ONE, ///< steady 1 (ON), no change for the whole period ONE_TO_FALL, ///< metastate allowing the timer change its state atomically without artefacts on the output pin FALL, ///< 16 fast PWM cycles with decreasing duty down to steady OFF FALL_TO_ZERO ///< metastate allowing the timer change its state atomically without artefacts on the output pin }; ///! Inner states of the finite automaton static States state = States::ZERO_START; bool bedPWMDisabled = 0; ///! Fast PWM counter is used in the RISE and FALL states (62.5kHz) static uint8_t slowCounter = 0; ///! Slow PWM counter is used in the ZERO and ONE states (62.5kHz/8 or 64) static uint8_t fastCounter = 0; ///! PWM counter for the whole cycle - a cache for soft_pwm_bed static uint8_t pwm = 0; ///! The slow PWM duty for the next 30Hz cycle ///! Set in the whole firmware at various places extern unsigned char soft_pwm_bed; /// fastMax - how many fast PWM steps to do in RISE and FALL states /// 16 is a good compromise between silenced bed ("smooth" edges) /// and not burning the switching MOSFET static const uint8_t fastMax = 16; /// Scaler 16->256 for fast PWM static const uint8_t fastShift = 4; /// Increment slow PWM counter by slowInc every ZERO or ONE state /// This allows for fine-tuning the basic PWM switching frequency /// A possible further optimization - use a 64 prescaler (instead of 8) /// increment slowCounter by 1 /// but use less bits of soft PWM - something like soft_pwm_bed >> 2 /// that may further reduce the CPU cycles required by the bed heating automaton /// Due to the nature of bed heating the reduced PID precision may not be a major issue, however doing 8x less ISR(timer0_ovf) may significantly improve the performance static const uint8_t slowInc = 1; ISR(TIMER0_OVF_vect) // timer compare interrupt service routine { switch(state){ case States::ZERO_START: if (bedPWMDisabled) break; pwm = soft_pwm_bed << 1;// expecting soft_pwm_bed to be 7bit! if( pwm != 0 ){ state = States::ZERO; // do nothing, let it tick once again after the 30Hz period } break; case States::ZERO: // end of state ZERO - we'll either stay in ZERO or change to RISE // In any case update our cache of pwm value for the next whole cycle from soft_pwm_bed slowCounter += slowInc; // this does software timer_clk/256 or less (depends on slowInc) if( slowCounter > pwm ){ return; } // otherwise moving towards RISE state = States::ZERO_TO_RISE; // and finalize the change in a transitional state RISE0 break; // even though it may look like the ZERO state may be glued together with the ZERO_TO_RISE, don't do it // the timer must tick once more in order to get rid of occasional output pin toggles. case States::ZERO_TO_RISE: // special state for handling transition between prescalers and switching inverted->non-inverted fast-PWM without toggling the output pin. // It must be done in consequent steps, otherwise the pin will get flipped up and down during one PWM cycle. // Also beware of the correct sequence of the following timer control registers initialization - it really matters! state = States::RISE; // prepare for standard RISE cycles fastCounter = fastMax - 1;// we'll do 16-1 cycles of RISE TCNT0 = 255; // force overflow on the next clock cycle TCCR0B = (1 << CS00); // change prescaler to 1, i.e. 62.5kHz TCCR0A &= ~(1 << COM0B0); // Clear OC0B on Compare Match, set OC0B at BOTTOM (non-inverting mode) break; case States::RISE: OCR0B = (fastMax - fastCounter) << fastShift; if( fastCounter ){ --fastCounter; } else { // end of RISE cycles, changing into state ONE state = States::RISE_TO_ONE; OCR0B = 255; // full duty TCNT0 = 254; // make the timer overflow in the next cycle // @@TODO these constants are still subject to investigation } break; case States::RISE_TO_ONE: state = States::ONE; OCR0B = 255; // full duty TCNT0 = 255; // make the timer overflow in the next cycle TCCR0B = (1 << CS01); // change prescaler to 8, i.e. 7.8kHz break; case States::ONE: // state ONE - we'll either stay in ONE or change to FALL OCR0B = 255; slowCounter += slowInc; // this does software timer_clk/256 or less if (!bedPWMDisabled){ //disable heating as soon as possible if( slowCounter < pwm ){ return; } if( (soft_pwm_bed << 1) >= (255 - slowInc - 1) ){ //@@TODO simplify & explain // if slowInc==2, soft_pwm == 251 will be the first to do short drops to zero. 252 will keep full heating return; // want full duty for the next ONE cycle again - so keep on heating and just wait for the next timer ovf } } else if (pwm > 200){ //if duty cycle is high and BED PWM is disabled keep heater on. Prevents overcooling return; } // otherwise moving towards FALL // @@TODO it looks like ONE_TO_FALL isn't necessary, there are no artefacts at all state = States::ONE;//_TO_FALL; // TCCR0B = (1 << CS00); // change prescaler to 1, i.e. 62.5kHz // break; // case States::ONE_TO_FALL: // OCR0B = 255; // zero duty state=States::FALL; fastCounter = fastMax - 1;// we'll do 16-1 cycles of RISE TCNT0 = 255; // force overflow on the next clock cycle TCCR0B = (1 << CS00); // change prescaler to 1, i.e. 62.5kHz // must switch to inverting mode already here, because it takes a whole PWM cycle and it would make a "1" at the end of this pwm cycle // COM0B1 remains set both in inverting and non-inverting mode TCCR0A |= (1 << COM0B0); // inverting mode break; case States::FALL: OCR0B = (fastMax - fastCounter) << fastShift; // this is the same as in RISE, because now we are setting the zero part of duty due to inverting mode //TCCR0A |= (1 << COM0B0); // already set in ONE_TO_FALL if( fastCounter ){ --fastCounter; } else { // end of FALL cycles, changing into state ZERO state = States::FALL_TO_ZERO; TCNT0 = 128; //@@TODO again - need to wait long enough to propagate the timer state changes OCR0B = 255; } break; case States::FALL_TO_ZERO: state = States::ZERO_START; // go to read new soft_pwm_bed value for the next cycle TCNT0 = 128; OCR0B = 255; TCCR0B = (1 << CS01); // change prescaler to 8, i.e. 7.8kHz break; } }