src/modules/tools/temperaturecontrol/TemperatureControl.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 // TODO : THIS FILE IS LAME, MUST BE MADE MUCH BETTER
   9
  10 #include "libs/Module.h"
  11 #include "libs/Kernel.h"
  12 #include <math.h>
  13 #include "TemperatureControl.h"
  14 #include "TemperatureControlPool.h"
  15 #include "libs/Pin.h"
  16 #include "modules/robot/Conveyor.h"
  17 #include "PublicDataRequest.h"
  18
  19 #include "PublicData.h"
  20 #include "ToolManagerPublicAccess.h"
  21 #include "StreamOutputPool.h"
  22 #include "Config.h"
  23 #include "checksumm.h"
  24 #include "Gcode.h"
  25 #include "SlowTicker.h"
  26 #include "Pauser.h"
  27 #include "ConfigValue.h"
  28 #include "PID_Autotuner.h"
  29 #include "SerialMessage.h"
  30 #include "utils.h"
  31
  32 // Temp sensor implementations:
  33 #include "Thermistor.h"
  34 #include "max31855.h"
  35 #include "AD8495.h"
  36
  37 #include "MRI_Hooks.h"
  38
  39 #define UNDEFINED -1
  40
  41 #define sensor_checksum                    CHECKSUM("sensor")
  42
  43 #define readings_per_second_checksum       CHECKSUM("readings_per_second")
  44 #define max_pwm_checksum                   CHECKSUM("max_pwm")
  45 #define pwm_frequency_checksum             CHECKSUM("pwm_frequency")
  46 #define bang_bang_checksum                 CHECKSUM("bang_bang")
  47 #define hysteresis_checksum                CHECKSUM("hysteresis")
  48 #define heater_pin_checksum                CHECKSUM("heater_pin")
  49 #define max_temp_checksum                  CHECKSUM("max_temp")
  50 #define min_temp_checksum                  CHECKSUM("min_temp")
  51
  52 #define get_m_code_checksum                CHECKSUM("get_m_code")
  53 #define set_m_code_checksum                CHECKSUM("set_m_code")
  54 #define set_and_wait_m_code_checksum       CHECKSUM("set_and_wait_m_code")
  55
  56 #define designator_checksum                CHECKSUM("designator")
  57
  58 #define p_factor_checksum                  CHECKSUM("p_factor")
  59 #define i_factor_checksum                  CHECKSUM("i_factor")
  60 #define d_factor_checksum                  CHECKSUM("d_factor")
  61
  62 #define i_max_checksum                     CHECKSUM("i_max")
  63 #define windup_checksum                    CHECKSUM("windup")
  64
  65 #define preset1_checksum                   CHECKSUM("preset1")
  66 #define preset2_checksum                   CHECKSUM("preset2")
  67
  68 TemperatureControl::TemperatureControl(uint16_t name, int index)
  69 {
  70     name_checksum= name;
  71     pool_index= index;
  72     waiting= false;
  73     temp_violated= false;
  74     sensor= nullptr;
  75     readonly= false;
  76 }
  77
  78 TemperatureControl::~TemperatureControl()
  79 {
  80     delete sensor;
  81 }
  82
  83 void TemperatureControl::on_module_loaded()
  84 {
  85
  86     // We start not desiring any temp
  87     this->target_temperature = UNDEFINED;
  88     this->sensor_settings= false; // set to true if sensor settings have been overriden
  89
  90     // Settings
  91     this->load_config();
  92
  93     // Register for events
  94     this->register_for_event(ON_GCODE_RECEIVED);
  95     this->register_for_event(ON_GET_PUBLIC_DATA);
  96
  97     if(!this->readonly) {
  98         this->register_for_event(ON_SECOND_TICK);
  99         this->register_for_event(ON_MAIN_LOOP);
 100         this->register_for_event(ON_SET_PUBLIC_DATA);
 101         this->register_for_event(ON_HALT);
 102     }
 103 }
 104
 105 void TemperatureControl::on_halt(void *arg)
 106 {
 107     if(arg == nullptr) {
 108         // turn off heater
 109         this->o = 0;
 110         this->heater_pin.set(0);
 111         this->target_temperature = UNDEFINED;
 112     }
 113 }
 114
 115 void TemperatureControl::on_main_loop(void *argument)
 116 {
 117     if (this->temp_violated) {
 118         this->temp_violated = false;
 119         THEKERNEL->streams->printf("Error: MINTEMP or MAXTEMP triggered. Check your temperature sensors!\n");
 120         THEKERNEL->streams->printf("HALT asserted - reset or M999 required\n");
 121         THEKERNEL->call_event(ON_HALT, nullptr);
 122     }
 123 }
 124
 125 // Get configuration from the config file
 126 void TemperatureControl::load_config()
 127 {
 128
 129     // General config
 130     this->set_m_code          = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, set_m_code_checksum)->by_default(104)->as_number();
 131     this->set_and_wait_m_code = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, set_and_wait_m_code_checksum)->by_default(109)->as_number();
 132     this->get_m_code          = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, get_m_code_checksum)->by_default(105)->as_number();
 133     this->readings_per_second = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, readings_per_second_checksum)->by_default(20)->as_number();
 134
 135     this->designator          = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, designator_checksum)->by_default(string("T"))->as_string();
 136
 137     // Max and min temperatures we are not allowed to get over (Safety)
 138     this->max_temp = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, max_temp_checksum)->by_default(300)->as_number();
 139     this->min_temp = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, min_temp_checksum)->by_default(0)->as_number();
 140
 141     // Heater pin
 142     this->heater_pin.from_string( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, heater_pin_checksum)->by_default("nc")->as_string());
 143     if(this->heater_pin.connected()){
 144         this->readonly= false;
 145         this->heater_pin.as_output();
 146
 147     } else {
 148         this->readonly= true;
 149     }
 150
 151     // For backward compatibility, default to a thermistor sensor.
 152     std::string sensor_type = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, sensor_checksum)->by_default("thermistor")->as_string();
 153
 154     // Instantiate correct sensor (TBD: TempSensor factory?)
 155     delete sensor;
 156     sensor = nullptr; // In case we fail to create a new sensor.
 157     if(sensor_type.compare("thermistor") == 0) {
 158         sensor = new Thermistor();
 159     } else if(sensor_type.compare("max31855") == 0) {
 160         sensor = new Max31855();
 161     } else if(sensor_type.compare("ad8495") == 0) {
 162         sensor = new AD8495();
 163     } else {
 164         sensor = new TempSensor(); // A dummy implementation
 165     }
 166     sensor->UpdateConfig(temperature_control_checksum, this->name_checksum);
 167
 168     this->preset1 = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, preset1_checksum)->by_default(0)->as_number();
 169     this->preset2 = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, preset2_checksum)->by_default(0)->as_number();
 170
 171
 172     // sigma-delta output modulation
 173     this->o = 0;
 174
 175     if(!this->readonly) {
 176         // used to enable bang bang control of heater
 177         this->use_bangbang = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, bang_bang_checksum)->by_default(false)->as_bool();
 178         this->hysteresis = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, hysteresis_checksum)->by_default(2)->as_number();
 179         this->windup = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, windup_checksum)->by_default(false)->as_bool();
 180         this->heater_pin.max_pwm( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, max_pwm_checksum)->by_default(255)->as_number() );
 181         this->heater_pin.set(0);
 182         set_low_on_debug(heater_pin.port_number, heater_pin.pin);
 183         // activate SD-DAC timer
 184         THEKERNEL->slow_ticker->attach( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, pwm_frequency_checksum)->by_default(2000)->as_number(), &heater_pin, &Pwm::on_tick);
 185     }
 186
 187
 188     // reading tick
 189     THEKERNEL->slow_ticker->attach( this->readings_per_second, this, &TemperatureControl::thermistor_read_tick );
 190     this->PIDdt = 1.0 / this->readings_per_second;
 191
 192     // PID
 193     setPIDp( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, p_factor_checksum)->by_default(10 )->as_number() );
 194     setPIDi( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, i_factor_checksum)->by_default(0.3f)->as_number() );
 195     setPIDd( THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, d_factor_checksum)->by_default(200)->as_number() );
 196
 197     if(!this->readonly) {
 198         // set to the same as max_pwm by default
 199         this->i_max = THEKERNEL->config->value(temperature_control_checksum, this->name_checksum, i_max_checksum   )->by_default(this->heater_pin.max_pwm())->as_number();
 200     }
 201
 202     this->iTerm = 0.0;
 203     this->lastInput = -1.0;
 204     this->last_reading = 0.0;
 205 }
 206
 207 void TemperatureControl::on_gcode_received(void *argument)
 208 {
 209     Gcode *gcode = static_cast<Gcode *>(argument);
 210     if (gcode->has_m) {
 211
 212         if( gcode->m == this->get_m_code ) {
 213             char buf[32]; // should be big enough for any status
 214             int n = snprintf(buf, sizeof(buf), "%s:%3.1f /%3.1f @%d ", this->designator.c_str(), this->get_temperature(), ((target_temperature <= 0) ? 0.0 : target_temperature), this->o);
 215             gcode->txt_after_ok.append(buf, n);
 216             return;
 217         }
 218
 219         if (gcode->m == 305) { // set or get sensor settings
 220             if (gcode->has_letter('S') && (gcode->get_value('S') == this->pool_index)) {
 221                 TempSensor::sensor_options_t args= gcode->get_args();
 222                 args.erase('S'); // don't include the S
 223                 if(args.size() > 0) {
 224                     // set the new options
 225                     if(sensor->set_optional(args)) {
 226                         this->sensor_settings= true;
 227                     }else{
 228                         gcode->stream->printf("Unable to properly set sensor settings, make sure you specify all required values\n");
 229                     }
 230                 }else{
 231                     // don't override
 232                     this->sensor_settings= false;
 233                 }
 234
 235             }else if(!gcode->has_letter('S')) {
 236                 gcode->stream->printf("%s(S%d): using %s\n", this->designator.c_str(), this->pool_index, this->readonly?"Readonly" : this->use_bangbang?"Bangbang":"PID");
 237                 sensor->get_raw();
 238                 TempSensor::sensor_options_t options;
 239                 if(sensor->get_optional(options)) {
 240                     for(auto &i : options) {
 241                         // foreach optional value
 242                         gcode->stream->printf("%s(S%d): %c %1.18f\n", this->designator.c_str(), this->pool_index, i.first, i.second);
 243                     }
 244                 }
 245             }
 246
 247             return;
 248         }
 249
 250         // readonly sensors don't handle the rest
 251         if(this->readonly) return;
 252
 253         if (gcode->m == 143) {
 254             if (gcode->has_letter('S') && (gcode->get_value('S') == this->pool_index)) {
 255                 if(gcode->has_letter('P')) {
 256                     max_temp= gcode->get_value('P');
 257
 258                 } else {
 259                     gcode->stream->printf("Nothing set NOTE Usage is M143 S0 P300 where <S> is the hotend index and <P> is the maximum temp to set\n");
 260                 }
 261
 262             }else if(gcode->get_num_args() == 0) {
 263                 gcode->stream->printf("Maximum temperature for %s(%d) is %f°C\n", this->designator.c_str(), this->pool_index, max_temp);
 264             }
 265
 266         } else if (gcode->m == 301) {
 267             if (gcode->has_letter('S') && (gcode->get_value('S') == this->pool_index)) {
 268                 if (gcode->has_letter('P'))
 269                     setPIDp( gcode->get_value('P') );
 270                 if (gcode->has_letter('I'))
 271                     setPIDi( gcode->get_value('I') );
 272                 if (gcode->has_letter('D'))
 273                     setPIDd( gcode->get_value('D') );
 274                 if (gcode->has_letter('X'))
 275                     this->i_max = gcode->get_value('X');
 276                 if (gcode->has_letter('Y'))
 277                     this->heater_pin.max_pwm(gcode->get_value('Y'));
 278
 279             }else if(!gcode->has_letter('S')) {
 280                 gcode->stream->printf("%s(S%d): Pf:%g If:%g Df:%g X(I_max):%g max pwm: %d O:%d\n", this->designator.c_str(), this->pool_index, this->p_factor, this->i_factor / this->PIDdt, this->d_factor * this->PIDdt, this->i_max, this->heater_pin.max_pwm(), o);
 281             }
 282
 283         } else if (gcode->m == 500 || gcode->m == 503) { // M500 saves some volatile settings to config override file, M503 just prints the settings
 284             gcode->stream->printf(";PID settings:\nM301 S%d P%1.4f I%1.4f D%1.4f X%1.4f Y%d\n", this->pool_index, this->p_factor, this->i_factor / this->PIDdt, this->d_factor * this->PIDdt, this->i_max, this->heater_pin.max_pwm());
 285
 286             gcode->stream->printf(";Max temperature setting:\nM143 S%d P%1.4f\n", this->pool_index, this->max_temp);
 287
 288             if(this->sensor_settings) {
 289                 // get or save any sensor specific optional values
 290                 TempSensor::sensor_options_t options;
 291                 if(sensor->get_optional(options) && !options.empty()) {
 292                     gcode->stream->printf(";Optional temp sensor specific settings:\nM305 S%d", this->pool_index);
 293                     for(auto &i : options) {
 294                         gcode->stream->printf(" %c%1.18f", i.first, i.second);
 295                     }
 296                     gcode->stream->printf("\n");
 297                 }
 298             }
 299
 300         } else if( ( gcode->m == this->set_m_code || gcode->m == this->set_and_wait_m_code ) && gcode->has_letter('S')) {
 301             // this only gets handled if it is not controlled by the tool manager or is active in the toolmanager
 302             this->active = true;
 303
 304             // this is safe as old configs as well as single extruder configs the toolmanager will not be running so will return false
 305             // this will also ignore anything that the tool manager is not controlling and return false, otherwise it returns the active tool
 306             void *returned_data;
 307             bool ok = PublicData::get_value( tool_manager_checksum, is_active_tool_checksum, this->name_checksum, &returned_data );
 308             if (ok) {
 309                 uint16_t active_tool_name =  *static_cast<uint16_t *>(returned_data);
 310                 this->active = (active_tool_name == this->name_checksum);
 311             }
 312
 313             if(this->active) {
 314                 // required so temp change happens in order
 315                 THEKERNEL->conveyor->wait_for_empty_queue();
 316
 317                 float v = gcode->get_value('S');
 318
 319                 if (v == 0.0) {
 320                     this->target_temperature = UNDEFINED;
 321                     this->heater_pin.set((this->o = 0));
 322                 } else {
 323                     this->set_desired_temperature(v);
 324                     // wait for temp to be reached, no more gcodes will be fetched until this is complete
 325                     if( gcode->m == this->set_and_wait_m_code) {
 326                         if(isinf(get_temperature()) && isinf(sensor->get_temperature())) {
 327                             THEKERNEL->streams->printf("Temperature reading is unreliable HALT asserted - reset or M999 required\n");
 328                             THEKERNEL->call_event(ON_HALT, nullptr);
 329                             return;
 330                         }
 331
 332                         this->waiting = true; // on_second_tick will announce temps
 333                         while ( get_temperature() < target_temperature ) {
 334                             THEKERNEL->call_event(ON_IDLE, this);
 335                             // check if ON_HALT was called (usually by kill button)
 336                             if(THEKERNEL->is_halted() || this->target_temperature == UNDEFINED) {
 337                                 THEKERNEL->streams->printf("Wait on temperature aborted by kill\n");
 338                                 break;
 339                             }
 340                         }
 341                         this->waiting = false;
 342                     }
 343                 }
 344             }
 345         }
 346     }
 347 }
 348
 349 void TemperatureControl::on_get_public_data(void *argument)
 350 {
 351     PublicDataRequest *pdr = static_cast<PublicDataRequest *>(argument);
 352
 353     if(!pdr->starts_with(temperature_control_checksum)) return;
 354
 355     if(pdr->second_element_is(pool_index_checksum)) {
 356         // asking for our instance pointer if we have this pool_index
 357         if(pdr->third_element_is(this->pool_index)) {
 358             static void *return_data;
 359             return_data = this;
 360             pdr->set_data_ptr(&return_data);
 361             pdr->set_taken();
 362         }
 363
 364     }else if(pdr->second_element_is(poll_controls_checksum)) {
 365         // polling for all temperature controls
 366         // add our data to the list which is passed in via the data_ptr
 367
 368         std::vector<struct pad_temperature> *v= static_cast<std::vector<pad_temperature>*>(pdr->get_data_ptr());
 369
 370         struct pad_temperature t;
 371         // setup data
 372         t.current_temperature = this->get_temperature();
 373         t.target_temperature = (target_temperature <= 0) ? 0 : this->target_temperature;
 374         t.pwm = this->o;
 375         t.designator= this->designator;
 376         t.id= this->name_checksum;
 377         v->push_back(t);
 378         pdr->set_taken();
 379
 380     }else if(pdr->second_element_is(current_temperature_checksum)) {
 381         // if targeted at us
 382         if(pdr->third_element_is(this->name_checksum)) {
 383             // ok this is targeted at us, so set the requ3sted data in the pointer passed into us
 384             struct pad_temperature *t= static_cast<pad_temperature*>(pdr->get_data_ptr());
 385             t->current_temperature = this->get_temperature();
 386             t->target_temperature = (target_temperature <= 0) ? 0 : this->target_temperature;
 387             t->pwm = this->o;
 388             t->designator= this->designator;
 389             t->id= this->name_checksum;
 390             pdr->set_taken();
 391         }
 392     }
 393
 394 }
 395
 396 void TemperatureControl::on_set_public_data(void *argument)
 397 {
 398     PublicDataRequest *pdr = static_cast<PublicDataRequest *>(argument);
 399
 400     if(!pdr->starts_with(temperature_control_checksum)) return;
 401
 402     if(!pdr->second_element_is(this->name_checksum)) return;
 403
 404     // ok this is targeted at us, so set the temp
 405     // NOTE unlike the M code this will set the temp now not when the queue is empty
 406     float t = *static_cast<float *>(pdr->get_data_ptr());
 407     this->set_desired_temperature(t);
 408     pdr->set_taken();
 409 }
 410
 411 void TemperatureControl::set_desired_temperature(float desired_temperature)
 412 {
 413     // Never go over the configured max temperature
 414     if( desired_temperature > this->max_temp ){
 415         desired_temperature = this->max_temp;
 416     }
 417
 418     if (desired_temperature == 1.0F)
 419         desired_temperature = preset1;
 420     else if (desired_temperature == 2.0F)
 421         desired_temperature = preset2;
 422
 423     float last_target_temperature= target_temperature;
 424     target_temperature = desired_temperature;
 425     if (desired_temperature <= 0.0F){
 426         // turning it off
 427         heater_pin.set((this->o = 0));
 428
 429     }else if(last_target_temperature <= 0.0F) {
 430         // if it was off and we are now turning it on we need to initialize
 431         this->lastInput= last_reading;
 432         // set to whatever the output currently is See http://brettbeauregard.com/blog/2011/04/improving-the-beginner%E2%80%99s-pid-initialization/
 433         this->iTerm= this->o;
 434         if (this->iTerm > this->i_max) this->iTerm = this->i_max;
 435         else if (this->iTerm < 0.0) this->iTerm = 0.0;
 436     }
 437 }
 438
 439 float TemperatureControl::get_temperature()
 440 {
 441     return last_reading;
 442 }
 443
 444 uint32_t TemperatureControl::thermistor_read_tick(uint32_t dummy)
 445 {
 446     float temperature = sensor->get_temperature();
 447     if(!this->readonly && target_temperature > 2) {
 448         if (isinf(temperature) || temperature < min_temp || temperature > max_temp) {
 449             this->temp_violated = true;
 450             target_temperature = UNDEFINED;
 451             heater_pin.set((this->o = 0));
 452         } else {
 453             pid_process(temperature);
 454         }
 455     }
 456
 457     last_reading = temperature;
 458     return 0;
 459 }
 460
 461 /**
 462  * Based on https://github.com/br3ttb/Arduino-PID-Library
 463  */
 464 void TemperatureControl::pid_process(float temperature)
 465 {
 466     if(use_bangbang) {
 467         // bang bang is very simple, if temp is < target - hysteresis turn on full else if  temp is > target + hysteresis turn heater off
 468         // good for relays
 469         if(temperature > (target_temperature + hysteresis) && this->o > 0) {
 470             heater_pin.set(false);
 471             this->o = 0; // for display purposes only
 472
 473         } else if(temperature < (target_temperature - hysteresis) && this->o <= 0) {
 474             if(heater_pin.max_pwm() >= 255) {
 475                 // turn on full
 476                 this->heater_pin.set(true);
 477                 this->o = 255; // for display purposes only
 478             } else {
 479                 // only to whatever max pwm is configured
 480                 this->heater_pin.pwm(heater_pin.max_pwm());
 481                 this->o = heater_pin.max_pwm(); // for display purposes only
 482             }
 483         }
 484         return;
 485     }
 486
 487     // regular PID control
 488     float error = target_temperature - temperature;
 489
 490     float new_I = this->iTerm + (error * this->i_factor);
 491     if (new_I > this->i_max) new_I = this->i_max;
 492     else if (new_I < 0.0) new_I = 0.0;
 493     if(!this->windup) this->iTerm= new_I;
 494
 495     float d = (temperature - this->lastInput);
 496
 497     // calculate the PID output
 498     // TODO does this need to be scaled by max_pwm/256? I think not as p_factor already does that
 499     this->o = (this->p_factor * error) + new_I - (this->d_factor * d);
 500
 501     if (this->o >= heater_pin.max_pwm())
 502         this->o = heater_pin.max_pwm();
 503     else if (this->o < 0)
 504         this->o = 0;
 505     else if(this->windup)
 506         this->iTerm = new_I; // Only update I term when output is not saturated.
 507
 508     this->heater_pin.pwm(this->o);
 509     this->lastInput = temperature;
 510 }
 511
 512 void TemperatureControl::on_second_tick(void *argument)
 513 {
 514     if (waiting)
 515         THEKERNEL->streams->printf("%s:%3.1f /%3.1f @%d\n", designator.c_str(), get_temperature(), ((target_temperature <= 0) ? 0.0 : target_temperature), o);
 516 }
 517
 518 void TemperatureControl::setPIDp(float p)
 519 {
 520     this->p_factor = p;
 521 }
 522
 523 void TemperatureControl::setPIDi(float i)
 524 {
 525     this->i_factor = i * this->PIDdt;
 526 }
 527
 528 void TemperatureControl::setPIDd(float d)
 529 {
 530     this->d_factor = d / this->PIDdt;
 531 }