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 "libs/actuators/StepperMotor.h"
  14 #include <mri.h>
  15
  16 /* The extruder module controls a filament extruder for 3D printing: http://en.wikipedia.org/wiki/Fused_deposition_modeling
  17 * 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 )
  18 * or the head moves, and the extruder moves plastic at a speed proportional to the movement of the head ( FOLLOW mode here ).
  19 */
  20
  21 Extruder::Extruder() {
  22     this->absolute_mode = true;
  23     this->step_counter = 0;
  24     this->counter_increment = 0;
  25     this->paused = false;
  26 }
  27
  28 void Extruder::on_module_loaded() {
  29
  30     // Do not do anything if not enabledd
  31     if( this->kernel->config->value( extruder_module_enable_checksum )->by_default(false)->as_bool() == false ){ return; }
  32
  33     // Settings
  34     this->on_config_reload(this);
  35
  36     // We start with the enable pin off
  37     this->en_pin.set(1);
  38
  39     // We work on the same Block as Stepper, so we need to know when it gets a new one and drops one
  40     register_for_event(ON_CONFIG_RELOAD);
  41     this->register_for_event(ON_BLOCK_BEGIN);
  42     this->register_for_event(ON_BLOCK_END);
  43     this->register_for_event(ON_GCODE_RECEIVED);
  44     this->register_for_event(ON_GCODE_EXECUTE);
  45     this->register_for_event(ON_PLAY);
  46     this->register_for_event(ON_PAUSE);
  47     this->register_for_event(ON_SPEED_CHANGE);
  48
  49     // Start values
  50     this->target_position = 0;
  51     this->current_position = 0;
  52     this->current_steps = 0;
  53     this->current_block = NULL;
  54     this->mode = OFF;
  55
  56     // Update speed every *acceleration_ticks_per_second*
  57     // TODO: Make this an independent setting
  58     this->kernel->slow_ticker->attach( this->kernel->stepper->acceleration_ticks_per_second , this, &Extruder::acceleration_tick );
  59
  60     // Stepper motor object for the extruder
  61     this->stepper_motor  = this->kernel->step_ticker->add_stepper_motor( new StepperMotor(&step_pin, &dir_pin, &en_pin) );
  62     this->stepper_motor->attach(this, &Extruder::stepper_motor_finished_move );
  63
  64 }
  65
  66 // Get config
  67 void Extruder::on_config_reload(void* argument){
  68     this->microseconds_per_step_pulse = this->kernel->config->value(microseconds_per_step_pulse_checksum)->by_default(5)->as_number();
  69     this->steps_per_millimeter        = this->kernel->config->value(extruder_steps_per_mm_checksum      )->by_default(1)->as_number();
  70     this->feed_rate                   = this->kernel->config->value(default_feed_rate_checksum          )->by_default(1000)->as_number();
  71     this->acceleration                = this->kernel->config->value(extruder_acceleration_checksum      )->by_default(1000)->as_number();
  72     this->max_speed                   = this->kernel->config->value(extruder_max_speed_checksum         )->by_default(1000)->as_number();
  73
  74     this->step_pin.from_string(         this->kernel->config->value(extruder_step_pin_checksum          )->by_default("nc" )->as_string())->as_output();
  75     this->dir_pin.from_string(          this->kernel->config->value(extruder_dir_pin_checksum           )->by_default("nc" )->as_string())->as_output();
  76     this->en_pin.from_string(           this->kernel->config->value(extruder_en_pin_checksum            )->by_default("nc" )->as_string())->as_output();
  77
  78         // disable by default
  79         this->en_pin.set(1);
  80 }
  81
  82
  83 // When the play/pause button is set to pause, or a module calls the ON_PAUSE event
  84 void Extruder::on_pause(void* argument){
  85     this->paused = true;
  86     this->stepper_motor->pause();
  87 }
  88
  89 // When the play/pause button is set to play, or a module calls the ON_PLAY event
  90 void Extruder::on_play(void* argument){
  91     this->paused = false;
  92     this->stepper_motor->unpause();
  93 }
  94
  95
  96 void Extruder::on_gcode_received(void *argument){
  97     Gcode *gcode = static_cast<Gcode*>(argument);
  98
  99     // Gcodes to execute immediately
 100     if (gcode->has_m){
 101         if (gcode->m == 114){
 102             gcode->stream->printf("E:%4.1f ", this->current_position);
 103             gcode->add_nl = true;
 104             gcode->mark_as_taken();
 105         }
 106         if (gcode->m == 92 ){
 107             double spm = this->steps_per_millimeter;
 108             if (gcode->has_letter('E'))
 109                 spm = gcode->get_value('E');
 110             gcode->stream->printf("E:%g ", spm);
 111             gcode->add_nl = true;
 112             gcode->mark_as_taken();
 113         }
 114     }
 115
 116     // Gcodes to pass along to on_gcode_execute
 117     if( ( gcode->has_m && ( 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 ) ) ){
 118         gcode->mark_as_taken();
 119         if( this->kernel->conveyor->queue.size() == 0 ){
 120             this->kernel->call_event(ON_GCODE_EXECUTE, gcode );
 121         }else{
 122             Block* block = this->kernel->conveyor->queue.get_ref( this->kernel->conveyor->queue.size() - 1 );
 123             block->append_gcode(gcode);
 124         }
 125     }
 126
 127     // Add to the queue for on_gcode_execute to process
 128     if( gcode->has_g && gcode->g < 4 && gcode->has_letter('E') ){
 129         if( !gcode->has_letter('X') && !gcode->has_letter('Y') && !gcode->has_letter('Z') ){
 130             // This is a solo move, we add an empty block to the queue
 131             //If the queue is empty, execute immediatly, otherwise attach to the last added block
 132             if( this->kernel->conveyor->queue.size() == 0 ){
 133                 this->kernel->call_event(ON_GCODE_EXECUTE, gcode );
 134                 this->append_empty_block();
 135             }else{
 136                 Block* block = this->kernel->conveyor->queue.get_ref( this->kernel->conveyor->queue.size() - 1 );
 137                 block->append_gcode(gcode);
 138                 this->append_empty_block();
 139             }
 140         }
 141     }else{
 142         // This is for follow move
 143
 144     }
 145 }
 146
 147 // Append an empty block in the queue so that solo mode can pick it up
 148 Block* Extruder::append_empty_block(){
 149     this->kernel->conveyor->wait_for_queue(2);
 150     Block* block = this->kernel->conveyor->new_block();
 151     block->planner = this->kernel->planner;
 152     block->millimeters = 0;
 153     block->steps[0] = 0;
 154     block->steps[1] = 0;
 155     block->steps[2] = 0;
 156     // feed the block into the system. Will execute it if we are at the beginning of the queue
 157     block->ready();
 158
 159     return block;
 160 }
 161
 162 // Compute extrusion speed based on parameters and gcode distance of travel
 163 void Extruder::on_gcode_execute(void* argument){
 164     Gcode* gcode = static_cast<Gcode*>(argument);
 165
 166     // Absolute/relative mode
 167     if( gcode->has_m ){
 168         if( gcode->m == 82 ){ this->absolute_mode = true; }
 169         if( gcode->m == 83 ){ this->absolute_mode = false; }
 170         if( gcode->m == 84 ){ this->en_pin.set(1); }
 171         if (gcode->m == 92 ){
 172             if (gcode->has_letter('E')){
 173                 this->steps_per_millimeter = gcode->get_value('E');
 174                 this->current_steps = int(floor(this->steps_per_millimeter * this->current_position));
 175             }
 176         }
 177     }
 178
 179     // The mode is OFF by default, and SOLO or FOLLOW only if we need to extrude
 180     this->mode = OFF;
 181
 182     if( gcode->has_g ){
 183         // G92: Reset extruder position
 184         if( gcode->g == 92 ){
 185             gcode->mark_as_taken();
 186             if( gcode->has_letter('E') ){
 187                 this->current_position = gcode->get_value('E');
 188                 this->target_position  = this->current_position;
 189                 this->current_steps = int(floor(this->steps_per_millimeter * this->current_position));
 190             }else if( gcode->get_num_args() == 0){
 191                 this->current_position = 0.0;
 192                 this->target_position = this->current_position;
 193                 this->current_steps = 0;
 194             }
 195         }else if ((gcode->g == 0) || (gcode->g == 1)){
 196             // Extrusion length from 'G' Gcode
 197             if( gcode->has_letter('E' )){
 198                 // Get relative extrusion distance depending on mode ( in absolute mode we must substract target_position )
 199                 double extrusion_distance = gcode->get_value('E');
 200                 double relative_extrusion_distance = extrusion_distance;
 201                 if (this->absolute_mode)
 202                 {
 203                     relative_extrusion_distance -= this->target_position;
 204                     this->target_position = extrusion_distance;
 205                 }
 206                 else
 207                 {
 208                     this->target_position += relative_extrusion_distance;
 209                 }
 210
 211                 // If the robot is moving, we follow it's movement, otherwise, we move alone
 212                 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
 213                     this->mode = SOLO;
 214                     this->travel_distance = relative_extrusion_distance;
 215                 }else{
 216                     // We move proportionally to the robot's movement
 217                     this->mode = FOLLOW;
 218                     this->travel_ratio = relative_extrusion_distance / gcode->millimeters_of_travel;
 219                     // TODO: check resulting flowrate, limit robot speed if it exceeds max_speed
 220                 }
 221
 222                 this->en_pin.set(0);
 223             }
 224             if (gcode->has_letter('F'))
 225             {
 226                 this->feed_rate = gcode->get_value('F');
 227                 if (this->feed_rate > (this->max_speed * kernel->robot->seconds_per_minute))
 228                     this->feed_rate = this->max_speed * kernel->robot->seconds_per_minute;
 229                 feed_rate /= kernel->robot->seconds_per_minute;
 230             }
 231         }else if( gcode->g == 90 ){ this->absolute_mode = true;
 232         }else if( gcode->g == 91 ){ this->absolute_mode = false;
 233         }
 234     }
 235 }
 236
 237 // When a new block begins, either follow the robot, or step by ourselves ( or stay back and do nothing )
 238 void Extruder::on_block_begin(void* argument){
 239     Block* block = static_cast<Block*>(argument);
 240
 241
 242     if( this->mode == SOLO ){
 243         // In solo mode we take the block so we can move even if the stepper has nothing to do
 244
 245         this->current_position += this->travel_distance ;
 246
 247         int steps_to_step = abs(int(floor(this->steps_per_millimeter * this->travel_distance)));
 248
 249         if( steps_to_step != 0 ){
 250
 251             // We take the block, we have to release it or everything gets stuck
 252             block->take();
 253             this->current_block = block;
 254
 255             this->stepper_motor->steps_per_second = 0;
 256             this->stepper_motor->move( ( this->travel_distance > 0 ), steps_to_step);
 257
 258         }else{
 259             this->current_block = NULL;
 260         }
 261
 262     }else if( this->mode == FOLLOW ){
 263         // In non-solo mode, we just follow the stepper module
 264         this->travel_distance = block->millimeters * this->travel_ratio;
 265
 266         this->current_position += this->travel_distance;
 267
 268         int steps_to_step = abs(int(floor(this->steps_per_millimeter * this->travel_distance)));
 269
 270         if( steps_to_step != 0 ){
 271             block->take();
 272             this->current_block = block;
 273
 274             this->stepper_motor->move( ( this->travel_distance > 0 ), steps_to_step );
 275         }else{
 276             this->current_block = NULL;
 277         }
 278
 279     }else if( this->mode == OFF ){
 280         // No movement means we must reset our speed
 281         this->current_block = NULL;
 282         //this->stepper_motor->set_speed(0);
 283
 284     }
 285
 286 }
 287
 288 // When a block ends, pause the stepping interrupt
 289 void Extruder::on_block_end(void* argument){
 290     this->current_block = NULL;
 291 }
 292
 293 // Called periodically to change the speed to match acceleration or to match the speed of the robot
 294 uint32_t Extruder::acceleration_tick(uint32_t dummy){
 295
 296     // Avoid trying to work when we really shouldn't ( between blocks or re-entry )
 297     if( this->current_block == NULL ||  this->paused || this->mode != SOLO ){ return 0; }
 298
 299     uint32_t current_rate = this->stepper_motor->steps_per_second;
 300     uint32_t target_rate = int(floor(this->feed_rate * this->steps_per_millimeter));
 301
 302     if( current_rate < target_rate ){
 303         uint32_t rate_increase = int(floor((this->acceleration/this->kernel->stepper->acceleration_ticks_per_second)*this->steps_per_millimeter));
 304         current_rate = min( target_rate, current_rate + rate_increase );
 305     }
 306     if( current_rate > target_rate ){ current_rate = target_rate; }
 307
 308     // steps per second
 309     this->stepper_motor->set_speed(max(current_rate, this->kernel->stepper->minimum_steps_per_minute/60));
 310
 311     return 0;
 312 }
 313
 314 // Speed has been updated for the robot's stepper, we must update accordingly
 315 void Extruder::on_speed_change( void* argument ){
 316
 317     // Avoid trying to work when we really shouldn't ( between blocks or re-entry )
 318     if( this->current_block == NULL ||  this->paused || this->mode != FOLLOW || this->stepper_motor->moving != true ){ return; }
 319
 320     /*
 321     * nominal block duration = current block's steps / ( current block's nominal rate / 60 )
 322     * nominal extruder rate = extruder steps / nominal block duration
 323     * actual extruder rate = nominal extruder rate * ( ( stepper's steps per minute / 60 ) / ( current block's nominal rate / 60 ) )
 324     * 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 ) )
 325     * or simplified : extruder steps * ( stepper's steps per minute / 60 ) ) / current block's steps
 326     * or even : ( stepper steps per minute / 60 ) * ( extruder steps / current block's steps )
 327     */
 328
 329     this->stepper_motor->set_speed( max( ( this->kernel->stepper->trapezoid_adjusted_rate /60L) * ( (double)this->stepper_motor->steps_to_move / (double)this->current_block->steps_event_count ), this->kernel->stepper->minimum_steps_per_minute/60 ) );
 330
 331 }
 332
 333
 334
 335 // When the stepper has finished it's move
 336 uint32_t Extruder::stepper_motor_finished_move(uint32_t dummy){
 337
 338     //printf("extruder releasing\r\n");
 339
 340     if (this->current_block){ // this should always be true, but sometimes it isn't. TODO: find out why
 341         Block* block = this->current_block;
 342         this->current_block = NULL;
 343         block->release();
 344     }
 345     return 0;
 346
 347 }
 348