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