src/modules/tools/extruder/Extruder.cpp

   1 /*
   2     This file is part of Smoothie (http://smoothieware.org/). The motion control part is heavily based on Grbl (https://github.com/simen/grbl).
   3     Smoothie is free software: you can redistribute it and/or modify it under the terms of the GNU General Public License as published by the Free Software Foundation, either version 3 of the License, or (at your option) any later version.
   4     Smoothie is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for more details.
   5     You should have received a copy of the GNU General Public License along with Smoothie. If not, see <http://www.gnu.org/licenses/>.
   6 */
   7
   8 #include "libs/Module.h"
   9 #include "libs/Kernel.h"
  10 #include "modules/robot/Conveyor.h"
  11 #include "modules/robot/Block.h"
  12 #include "modules/tools/extruder/Extruder.h"
  13 #include <mri.h>
  14
  15 #define extruder_module_enable_checksum      CHECKSUM("extruder_module_enable")
  16 #define extruder_steps_per_mm_checksum       CHECKSUM("extruder_steps_per_mm")
  17 #define extruder_acceleration_checksum       CHECKSUM("extruder_acceleration")
  18 #define extruder_step_pin_checksum           CHECKSUM("extruder_step_pin")
  19 #define extruder_dir_pin_checksum            CHECKSUM("extruder_dir_pin")
  20 #define extruder_en_pin_checksum             CHECKSUM("extruder_en_pin")
  21 #define extruder_max_speed_checksum          CHECKSUM("extruder_max_speed")
  22
  23 #define extruder_checksum                    CHECKSUM("extruder")
  24
  25 #define default_feed_rate_checksum           CHECKSUM("default_feed_rate")
  26 #define steps_per_mm_checksum                CHECKSUM("steps_per_mm")
  27 #define acceleration_checksum                CHECKSUM("acceleration")
  28 #define step_pin_checksum                    CHECKSUM("step_pin")
  29 #define dir_pin_checksum                     CHECKSUM("dir_pin")
  30 #define en_pin_checksum                      CHECKSUM("en_pin")
  31 #define max_speed_checksum                   CHECKSUM("max_speed")
  32
  33 #define max(a,b) (((a) > (b)) ? (a) : (b))
  34
  35 /* The extruder module controls a filament extruder for 3D printing: http://en.wikipedia.org/wiki/Fused_deposition_modeling
  36 * It can work in two modes : either the head does not move, and the extruder moves the filament at a specified speed ( SOLO mode here )
  37 * or the head moves, and the extruder moves plastic at a speed proportional to the movement of the head ( FOLLOW mode here ).
  38 */
  39
  40 Extruder::Extruder( uint16_t config_identifier ) {
  41     this->absolute_mode = true;
  42     this->paused        = false;
  43     this->single_config = false;
  44     this->identifier    = config_identifier;
  45 }
  46
  47 void Extruder::on_module_loaded() {
  48
  49     // Settings
  50     this->on_config_reload(this);
  51
  52     // We start with the enable pin off
  53     this->en_pin.set(1);
  54
  55     // We work on the same Block as Stepper, so we need to know when it gets a new one and drops one
  56     register_for_event(ON_CONFIG_RELOAD);
  57     this->register_for_event(ON_BLOCK_BEGIN);
  58     this->register_for_event(ON_BLOCK_END);
  59     this->register_for_event(ON_GCODE_RECEIVED);
  60     this->register_for_event(ON_GCODE_EXECUTE);
  61     this->register_for_event(ON_PLAY);
  62     this->register_for_event(ON_PAUSE);
  63     this->register_for_event(ON_SPEED_CHANGE);
  64
  65     // Start values
  66     this->target_position = 0;
  67     this->current_position = 0;
  68     this->unstepped_distance = 0;
  69     this->current_block = NULL;
  70     this->mode = OFF;
  71
  72     // Update speed every *acceleration_ticks_per_second*
  73     // TODO: Make this an independent setting
  74     THEKERNEL->slow_ticker->attach( THEKERNEL->stepper->acceleration_ticks_per_second , this, &Extruder::acceleration_tick );
  75
  76     // Stepper motor object for the extruder
  77     this->stepper_motor  = THEKERNEL->step_ticker->add_stepper_motor( new StepperMotor(&step_pin, &dir_pin, &en_pin) );
  78     this->stepper_motor->attach(this, &Extruder::stepper_motor_finished_move );
  79
  80 }
  81
  82 // Get config
  83 void Extruder::on_config_reload(void* argument){
  84
  85     // If this module uses the old "single extruder" configuration style
  86     if( this->single_config ){
  87
  88         this->steps_per_millimeter        = THEKERNEL->config->value(extruder_steps_per_mm_checksum      )->by_default(1)->as_number();
  89         this->acceleration                = THEKERNEL->config->value(extruder_acceleration_checksum      )->by_default(1000)->as_number();
  90         this->max_speed                   = THEKERNEL->config->value(extruder_max_speed_checksum         )->by_default(1000)->as_number();
  91         this->feed_rate                   = THEKERNEL->config->value(default_feed_rate_checksum          )->by_default(1000)->as_number();
  92
  93         this->step_pin.from_string(         THEKERNEL->config->value(extruder_step_pin_checksum          )->by_default("nc" )->as_string())->as_output();
  94         this->dir_pin.from_string(          THEKERNEL->config->value(extruder_dir_pin_checksum           )->by_default("nc" )->as_string())->as_output();
  95         this->en_pin.from_string(           THEKERNEL->config->value(extruder_en_pin_checksum            )->by_default("nc" )->as_string())->as_output();
  96
  97     }else{
  98     // If this module was created with the new multi extruder configuration style
  99
 100         this->steps_per_millimeter        = THEKERNEL->config->value(extruder_checksum, this->identifier, steps_per_mm_checksum      )->by_default(1)->as_number();
 101         this->acceleration                = THEKERNEL->config->value(extruder_checksum, this->identifier, acceleration_checksum      )->by_default(1000)->as_number();
 102         this->max_speed                   = THEKERNEL->config->value(extruder_checksum, this->identifier, max_speed_checksum         )->by_default(1000)->as_number();
 103         this->feed_rate                   = THEKERNEL->config->value(                                     default_feed_rate_checksum )->by_default(1000)->as_number();
 104
 105         this->step_pin.from_string(         THEKERNEL->config->value(extruder_checksum, this->identifier, step_pin_checksum          )->by_default("nc" )->as_string())->as_output();
 106         this->dir_pin.from_string(          THEKERNEL->config->value(extruder_checksum, this->identifier, dir_pin_checksum           )->by_default("nc" )->as_string())->as_output();
 107         this->en_pin.from_string(           THEKERNEL->config->value(extruder_checksum, this->identifier, en_pin_checksum            )->by_default("nc" )->as_string())->as_output();
 108
 109     }
 110
 111     // disable by default
 112     this->en_pin.set(1);
 113
 114 }
 115
 116
 117 // When the play/pause button is set to pause, or a module calls the ON_PAUSE event
 118 void Extruder::on_pause(void* argument){
 119     this->paused = true;
 120     this->stepper_motor->pause();
 121 }
 122
 123 // When the play/pause button is set to play, or a module calls the ON_PLAY event
 124 void Extruder::on_play(void* argument){
 125     this->paused = false;
 126     this->stepper_motor->unpause();
 127 }
 128
 129
 130 void Extruder::on_gcode_received(void *argument){
 131     Gcode *gcode = static_cast<Gcode*>(argument);
 132
 133     // Gcodes to execute immediately
 134     if (gcode->has_m){
 135         if (gcode->m == 114){
 136             gcode->stream->printf("E:%4.1f ", this->current_position);
 137             gcode->add_nl = true;
 138             gcode->mark_as_taken();
 139
 140         }else if (gcode->m == 92 ){
 141             double spm = this->steps_per_millimeter;
 142             if (gcode->has_letter('E'))
 143                 spm = gcode->get_value('E');
 144             gcode->stream->printf("E:%g ", spm);
 145             gcode->add_nl = true;
 146             gcode->mark_as_taken();
 147
 148         }else if (gcode->m == 500 || gcode->m == 503){// M500 saves some volatile settings to config override file, M503 just prints the settings
 149             gcode->stream->printf(";E Steps per mm:\nM92 E%1.4f\n", this->steps_per_millimeter);
 150             gcode->mark_as_taken();
 151             return;
 152         }
 153     }
 154
 155     // Gcodes to pass along to on_gcode_execute
 156     if( ( gcode->has_m && (gcode->m == 17 || gcode->m == 18 || gcode->m == 82 || gcode->m == 83 || gcode->m == 84 || gcode->m == 92 ) ) || ( gcode->has_g && gcode->g == 92 && gcode->has_letter('E') ) || ( gcode->has_g && ( gcode->g == 90 || gcode->g == 91 ) ) ){
 157         gcode->mark_as_taken();
 158         if( THEKERNEL->conveyor->queue.size() == 0 ){
 159             THEKERNEL->call_event(ON_GCODE_EXECUTE, gcode );
 160         }else{
 161             Block* block = THEKERNEL->conveyor->queue.get_ref( THEKERNEL->conveyor->queue.size() - 1 );
 162             block->append_gcode(gcode);
 163         }
 164     }
 165
 166     // Add to the queue for on_gcode_execute to process
 167     if( gcode->has_g && gcode->g < 4 && gcode->has_letter('E') ){
 168         if( !gcode->has_letter('X') && !gcode->has_letter('Y') && !gcode->has_letter('Z') ){
 169             // This is a solo move, we add an empty block to the queue
 170             //If the queue is empty, execute immediatly, otherwise attach to the last added block
 171             if( THEKERNEL->conveyor->queue.size() == 0 ){
 172                 THEKERNEL->call_event(ON_GCODE_EXECUTE, gcode );
 173                 this->append_empty_block();
 174             }else{
 175                 Block* block = THEKERNEL->conveyor->queue.get_ref( THEKERNEL->conveyor->queue.size() - 1 );
 176                 block->append_gcode(gcode);
 177                 this->append_empty_block();
 178             }
 179         }
 180     }else{
 181         // This is for follow move
 182
 183     }
 184 }
 185
 186 // Append an empty block in the queue so that solo mode can pick it up
 187 Block* Extruder::append_empty_block(){
 188     THEKERNEL->conveyor->wait_for_queue(2);
 189     Block* block = THEKERNEL->conveyor->new_block();
 190     block->planner = THEKERNEL->planner;
 191     block->millimeters = 0;
 192     block->steps[0] = 0;
 193     block->steps[1] = 0;
 194     block->steps[2] = 0;
 195     // feed the block into the system. Will execute it if we are at the beginning of the queue
 196     block->ready();
 197
 198     return block;
 199 }
 200
 201 // Compute extrusion speed based on parameters and gcode distance of travel
 202 void Extruder::on_gcode_execute(void* argument){
 203     Gcode* gcode = static_cast<Gcode*>(argument);
 204
 205     // Absolute/relative mode
 206     if( gcode->has_m ){
 207         if( gcode->m == 17 ){ this->en_pin.set(0); }
 208         if( gcode->m == 18 ){ this->en_pin.set(1); }
 209         if( gcode->m == 82 ){ this->absolute_mode = true; }
 210         if( gcode->m == 83 ){ this->absolute_mode = false; }
 211         if( gcode->m == 84 ){ this->en_pin.set(1); }
 212         if (gcode->m == 92 ){
 213             if (gcode->has_letter('E')){
 214                 this->steps_per_millimeter = gcode->get_value('E');
 215             }
 216         }
 217     }
 218
 219     // The mode is OFF by default, and SOLO or FOLLOW only if we need to extrude
 220     this->mode = OFF;
 221
 222     if( gcode->has_g ){
 223         // G92: Reset extruder position
 224         if( gcode->g == 92 ){
 225             gcode->mark_as_taken();
 226             if( gcode->has_letter('E') ){
 227                 this->current_position = gcode->get_value('E');
 228                 this->target_position  = this->current_position;
 229                 this->unstepped_distance = 0;
 230             }else if( gcode->get_num_args() == 0){
 231                 this->current_position = 0.0;
 232                 this->target_position = this->current_position;
 233                 this->unstepped_distance = 0;
 234             }
 235         }else if ((gcode->g == 0) || (gcode->g == 1)){
 236             // Extrusion length from 'G' Gcode
 237             if( gcode->has_letter('E' )){
 238                 // Get relative extrusion distance depending on mode ( in absolute mode we must substract target_position )
 239                 double extrusion_distance = gcode->get_value('E');
 240                 double relative_extrusion_distance = extrusion_distance;
 241                 if (this->absolute_mode)
 242                 {
 243                     relative_extrusion_distance -= this->target_position;
 244                     this->target_position = extrusion_distance;
 245                 }
 246                 else
 247                 {
 248                     this->target_position += relative_extrusion_distance;
 249                 }
 250
 251                 // If the robot is moving, we follow it's movement, otherwise, we move alone
 252                 if( fabs(gcode->millimeters_of_travel) < 0.0001 ){  // With floating numbers, we can have 0 != 0 ... beeeh. For more info see : http://upload.wikimedia.org/wikipedia/commons/0/0a/Cain_Henri_Vidal_Tuileries.jpg
 253                     this->mode = SOLO;
 254                     this->travel_distance = relative_extrusion_distance;
 255                 }else{
 256                     // We move proportionally to the robot's movement
 257                     this->mode = FOLLOW;
 258                     this->travel_ratio = relative_extrusion_distance / gcode->millimeters_of_travel;
 259                     // TODO: check resulting flowrate, limit robot speed if it exceeds max_speed
 260                 }
 261
 262                 this->en_pin.set(0);
 263             }
 264             if (gcode->has_letter('F'))
 265             {
 266                 this->feed_rate = gcode->get_value('F');
 267                 if (this->feed_rate > (this->max_speed * THEKERNEL->robot->seconds_per_minute))
 268                     this->feed_rate = this->max_speed * THEKERNEL->robot->seconds_per_minute;
 269                 feed_rate /= THEKERNEL->robot->seconds_per_minute;
 270             }
 271         }else if( gcode->g == 90 ){ this->absolute_mode = true;
 272         }else if( gcode->g == 91 ){ this->absolute_mode = false;
 273         }
 274     }
 275 }
 276
 277 // When a new block begins, either follow the robot, or step by ourselves ( or stay back and do nothing )
 278 void Extruder::on_block_begin(void* argument){
 279     Block* block = static_cast<Block*>(argument);
 280
 281
 282     if( this->mode == SOLO ){
 283         // In solo mode we take the block so we can move even if the stepper has nothing to do
 284
 285         this->current_position += this->travel_distance ;
 286
 287         int steps_to_step = abs(int(floor(this->steps_per_millimeter * (this->travel_distance +this->unstepped_distance) )));
 288
 289         if ( this->travel_distance > 0 ){
 290             this->unstepped_distance += this->travel_distance -(steps_to_step/this->steps_per_millimeter); //catch any overflow
 291         }   else {
 292             this->unstepped_distance += this->travel_distance +(steps_to_step/this->steps_per_millimeter); //catch any overflow
 293         }
 294
 295         if( steps_to_step != 0 ){
 296
 297             // We take the block, we have to release it or everything gets stuck
 298             block->take();
 299             this->current_block = block;
 300
 301             this->stepper_motor->steps_per_second = 0;
 302             this->stepper_motor->move( ( this->travel_distance > 0 ), steps_to_step);
 303
 304         }else{
 305             this->current_block = NULL;
 306         }
 307
 308     }else if( this->mode == FOLLOW ){
 309         // In non-solo mode, we just follow the stepper module
 310         this->travel_distance = block->millimeters * this->travel_ratio;
 311
 312         this->current_position += this->travel_distance;
 313
 314         int steps_to_step = abs(int(floor(this->steps_per_millimeter * (this->travel_distance + this->unstepped_distance) )));
 315
 316         if ( this->travel_distance > 0 ){
 317             this->unstepped_distance += this->travel_distance -(steps_to_step/this->steps_per_millimeter); //catch any overflow
 318         }   else {
 319             this->unstepped_distance += this->travel_distance +(steps_to_step/this->steps_per_millimeter); //catch any overflow
 320         }
 321
 322         if( steps_to_step != 0 ){
 323             block->take();
 324             this->current_block = block;
 325
 326             this->stepper_motor->move( ( this->travel_distance > 0 ), steps_to_step );
 327             this->on_speed_change(0); // initialise speed in case we get called first
 328         }else{
 329             this->current_block = NULL;
 330         }
 331
 332     }else if( this->mode == OFF ){
 333         // No movement means we must reset our speed
 334         this->current_block = NULL;
 335         //this->stepper_motor->set_speed(0);
 336
 337     }
 338
 339 }
 340
 341 // When a block ends, pause the stepping interrupt
 342 void Extruder::on_block_end(void* argument){
 343     this->current_block = NULL;
 344 }
 345
 346 // Called periodically to change the speed to match acceleration or to match the speed of the robot
 347 uint32_t Extruder::acceleration_tick(uint32_t dummy){
 348
 349     // Avoid trying to work when we really shouldn't ( between blocks or re-entry )
 350     if( this->current_block == NULL ||  this->paused || this->mode != SOLO ){ return 0; }
 351
 352     uint32_t current_rate = this->stepper_motor->steps_per_second;
 353     uint32_t target_rate = int(floor(this->feed_rate * this->steps_per_millimeter));
 354
 355     if( current_rate < target_rate ){
 356         uint32_t rate_increase = int(floor((this->acceleration/THEKERNEL->stepper->acceleration_ticks_per_second)*this->steps_per_millimeter));
 357         current_rate = min( target_rate, current_rate + rate_increase );
 358     }
 359     if( current_rate > target_rate ){ current_rate = target_rate; }
 360
 361     // steps per second
 362     this->stepper_motor->set_speed(max(current_rate, THEKERNEL->stepper->minimum_steps_per_minute/60));
 363
 364     return 0;
 365 }
 366
 367 // Speed has been updated for the robot's stepper, we must update accordingly
 368 void Extruder::on_speed_change( void* argument ){
 369
 370     // Avoid trying to work when we really shouldn't ( between blocks or re-entry )
 371     if( this->current_block == NULL ||  this->paused || this->mode != FOLLOW || this->stepper_motor->moving != true ){ return; }
 372
 373     /*
 374     * nominal block duration = current block's steps / ( current block's nominal rate / 60 )
 375     * nominal extruder rate = extruder steps / nominal block duration
 376     * actual extruder rate = nominal extruder rate * ( ( stepper's steps per minute / 60 ) / ( current block's nominal rate / 60 ) )
 377     * or actual extruder rate = ( ( extruder steps * ( current block's nominal_rate / 60 ) ) / current block's steps ) * ( ( stepper's steps per minute / 60 ) / ( current block's nominal rate / 60 ) )
 378     * or simplified : extruder steps * ( stepper's steps per minute / 60 ) ) / current block's steps
 379     * or even : ( stepper steps per minute / 60 ) * ( extruder steps / current block's steps )
 380     */
 381
 382     this->stepper_motor->set_speed( max( ( THEKERNEL->stepper->trapezoid_adjusted_rate /60.0) * ( (double)this->stepper_motor->steps_to_move / (double)this->current_block->steps_event_count ), THEKERNEL->stepper->minimum_steps_per_minute/60.0 ) );
 383
 384 }
 385
 386
 387
 388 // When the stepper has finished it's move
 389 uint32_t Extruder::stepper_motor_finished_move(uint32_t dummy){
 390
 391     //printf("extruder releasing\r\n");
 392
 393     if (this->current_block){ // this should always be true, but sometimes it isn't. TODO: find out why
 394         Block* block = this->current_block;
 395         this->current_block = NULL;
 396         block->release();
 397     }
 398     return 0;
 399
 400 }
 401