rework sensorless rehome; check traveled distance (with tolerance (#110)

config) Co-authored-by: Brandon Nance <[email protected]>
KalicoCrew · Dec 20, 2023 · 544e3ee · 544e3ee
1 parent 17c6d64
commit 544e3ee
Show file tree

Hide file tree

Showing 4 changed files with 81 additions and 42 deletions.
diff --git a/README.md b/README.md
@@ -52,6 +52,8 @@ If I want my printer to light itself on fire, I should be able to make my printe
 
 - [danger_options: expose the multi mcu homing timeout as a parameter](https://github.com/DangerKlippers/danger-klipper/pull/93)
 
+- [danger_options: option to configure the homing elapsed distance tolerance](https://github.com/DangerKlippers/danger-klipper/pull/110)
+
 - [temperature_mcu: add reference_voltage](https://github.com/DangerKlippers/danger-klipper/pull/99) ([klipper#5713](https://github.com/Klipper3d/klipper/pull/5713))
 
 - [stepper: current_change_dwell_time](https://github.com/DangerKlippers/danger-klipper/pull/90)

diff --git a/docs/Config_Reference.md b/docs/Config_Reference.md
@@ -73,36 +73,43 @@ pins such as "extra_mcu:ar9" may then be used elsewhere in the config
 [mcu my_extra_mcu]
 # See the "mcu" section for configuration parameters.
 ```
+
 ## ⚠️ Danger Options
+
 A collection of DangerKlipper-specific system options
+
 ```
 [danger_options]
-
-# If an unused config option or section should cause an error
-# if False, will warn but allow klipper to still run
-error_on_unused_config_options: True
-
-# If statistics should be logged
-# (helpful for keeping the log clean during development)
-log_statistics: True
-
-# If the config file should be logged at startup
-log_config_file_at_startup: True
-
-# If the bed mesh should be logged on startup
-# (helpful for keeping the log clean during development)
-log_bed_mesh_at_startup: True
-
-# If we should log detailed crash info when an exception occurs
-# Most of it is overly-verbose and fluff and we still get a stack trace
-# for normal exceptions, so setting to False can help save time while developing
-log_shutdown_info: True
-
-# Allows modules in `plugins` to override modules of the same name in `extras`
-allow_plugin_override: False
-
-# The timeout (in seconds) for MCU synchronization during the homing process when multiple MCUs are in use.
-multi_mcu_trsync_timeout: 0.025
+#error_on_unused_config_options: True
+#   If an unused config option or section should cause an error
+#   if False, will warn but allow klipper to still run.
+#   The default is True.
+#log_statistics: True
+#   If statistics should be logged
+#   (helpful for keeping the log clean during development)
+#   The default is True.
+#log_config_file_at_startup: True
+#   If the config file should be logged at startup
+#   The default is True.
+#log_bed_mesh_at_startup: True
+#   If the bed mesh should be logged on startup
+#   (helpful for keeping the log clean during development)
+#   The default is True.
+#log_shutdown_info: True
+#   If we should log detailed crash info when an exception occurs
+#   Most of it is overly-verbose and fluff and we still get a stack trace
+#   for normal exceptions, so setting to False can help save time while developing
+#   The default is True.
+#allow_plugin_override: False
+#   Allows modules in `plugins` to override modules of the same name in `extras`
+#   The default is False.
+#multi_mcu_trsync_timeout: 0.025
+#   The timeout (in seconds) for MCU synchronization during the homing process when
+#   multiple MCUs are in use. The default is 0.025
+#homing_elapsed_distance_tolerance: 0.5
+#   Tolerance (in mm) for distance moved in the second homing. Ensures the
+#   second homing distance closely matches the `min_home_dist` when using
+#   sensorless homing. The default is 0.5mm.
 ```
 
 ## Common kinematic settings
@@ -365,7 +372,7 @@ example deltesian kinematics config file.
 
 Only parameters specific to deltesian printers are described here - see
 [common kinematic settings](#common-kinematic-settings) for available
- parameters.
+parameters.
 
 ```
 [printer]
@@ -914,6 +921,7 @@ See the [bed mesh guide](Bed_Mesh.md) and
 [command reference](G-Codes.md#bed_mesh) for additional information.
 
 Visual Examples:
+
 ```
  rectangular bed, probe_count = 3, 3:
              x---x---x (max_point)
@@ -1241,7 +1249,6 @@ extended [G-Code command](G-Codes.md#z_tilt) becomes available.
 #   The default is conservative.
 ```
 
-
 ### [quad_gantry_level]
 
 Moving gantry leveling using 4 independently controlled Z motors.
@@ -1251,6 +1258,7 @@ WARNING: Using this on a moving bed may lead to undesirable results.
 If this section is present then a QUAD_GANTRY_LEVEL extended G-Code
 command becomes available. This routine assumes the following Z motor
 configuration:
+
 ```
  ----------------
  |Z1          Z2|
@@ -1261,6 +1269,7 @@ configuration:
  |Z           Z3|
  ----------------
 ```
+
 Where x is the 0, 0 point on the bed
 
 ```
@@ -1669,6 +1678,7 @@ Enable the "M118" and "RESPOND" extended
 ```
 
 ### [exclude_object]
+
 Enables support to exclude or cancel individual objects during the printing
 process.
 
@@ -1885,7 +1895,7 @@ aliases_<name>:
 
 Include file support. One may include additional config file from the
 main printer config file. Wildcards may also be used (eg,
-"configs/*.cfg").
+"configs/\*.cfg").
 
 ```
 [include my_other_config.cfg]
@@ -4890,8 +4900,8 @@ Octoprint as they will conflict, and 1 will fail to initialize
 properly likely aborting your print.
 
 If you use Octoprint and stream gcode over the serial port instead of
-printing from virtual_sd, then remo **M1** and **M0** from *Pausing commands*
-in *Settings > Serial Connection > Firmware & protocol* will prevent
+printing from virtual_sd, then remo **M1** and **M0** from _Pausing commands_
+in _Settings > Serial Connection > Firmware & protocol_ will prevent
 the need to start print on the Palette 2 and unpausing in Octoprint
 for your print to begin.
 
@@ -4914,7 +4924,7 @@ serial:
 ### [angle]
 
 Magnetic hall angle sensor support for reading stepper motor angle
-shaft measurements using a1333, as5047d, or tle5012b SPI chips.  The
+shaft measurements using a1333, as5047d, or tle5012b SPI chips. The
 measurements are available via the [API Server](API_Server.md) and
 [motion analysis tool](Debugging.md#motion-analysis-and-data-logging).
 See the [G-Code reference](G-Codes.md#angle) for available commands.
@@ -4982,8 +4992,8 @@ It is generally recommended to only use I2C devices that are on the
 same printed circuit board as the micro-controller.
 
 Most Klipper micro-controller implementations only support an
-`i2c_speed` of 100000 (*standard mode*, 100kbit/s). The Klipper "Linux"
-micro-controller supports a 400000 speed (*fast mode*, 400kbit/s), but it must be
+`i2c_speed` of 100000 (_standard mode_, 100kbit/s). The Klipper "Linux"
+micro-controller supports a 400000 speed (_fast mode_, 400kbit/s), but it must be
 [set in the operating system](RPi_microcontroller.md#optional-enabling-i2c)
 and the `i2c_speed` parameter is otherwise ignored. The Klipper
 "RP2040" micro-controller and ATmega AVR family support a rate of 400000

diff --git a/klippy/extras/danger_options.py b/klippy/extras/danger_options.py
@@ -19,6 +19,9 @@ def __init__(self, config):
         self.multi_mcu_trsync_timeout = config.getfloat(
             "multi_mcu_trsync_timeout", 0.025, minval=0.0
         )
+        self.homing_elapsed_distance_tolerance = config.getfloat(
+            "homing_elapsed_distance_tolerance", 0.5, minval=0.0
+        )
 
 
 def load_config(config):

diff --git a/klippy/extras/homing.py b/klippy/extras/homing.py
@@ -50,6 +50,7 @@ def __init__(self, printer, endstops, toolhead=None):
         self.toolhead = toolhead
         self.stepper_positions = []
         self.distance_elapsed = []
+        self.danger_options = printer.lookup_object("danger_options")
 
     def get_mcu_endstops(self):
         return [es for es, name in self.endstops]
@@ -197,6 +198,25 @@ def check_no_movement(self):
                 return sp.endstop_name
         return None
 
+    def moved_less_than_dist(self, min_dist, homing_axes):
+        homing_axis_distances = [
+            dist
+            for i, dist in enumerate(self.distance_elapsed)
+            if i in homing_axes
+        ]
+        distance_tolerance = (
+            self.danger_options.homing_elapsed_distance_tolerance
+        )
+        if any(
+            [
+                abs(dist) < min_dist
+                and min_dist - abs(dist) >= distance_tolerance
+                for dist in homing_axis_distances
+            ]
+        ):
+            return True
+        return False
+
 
 # State tracking of homing requests
 class Homing:
@@ -275,18 +295,12 @@ def home_rails(self, rails, forcepos, movepos):
 
         hmove.homing_move(homepos, hi.speed)
 
-        homing_axis_distances = [
-            dist
-            for i, dist in enumerate(hmove.distance_elapsed)
-            if i in homing_axes
-        ]
         needs_rehome = False
         retract_dist = hi.retract_dist
-        if any(
-            [abs(dist) < hi.min_home_dist for dist in homing_axis_distances]
-        ):
+        if hmove.moved_less_than_dist(hi.min_home_dist, homing_axes):
             needs_rehome = True
             retract_dist = hi.min_home_dist
+
         # Perform second home
         if retract_dist:
             logging.info("needs rehome: %s", needs_rehome)
@@ -319,6 +333,16 @@ def home_rails(self, rails, forcepos, movepos):
                         "Endstop %s still triggered after retract"
                         % (hmove.check_no_movement(),)
                     )
+                if (
+                    hi.use_sensorless_homing
+                    and needs_rehome
+                    and hmove.moved_less_than_dist(
+                        hi.min_home_dist, homing_axes
+                    )
+                ):
+                    raise self.printer.command_error(
+                        "Early homing trigger on second home!"
+                    )
                 if hi.retract_dist:
                     # Retract (again)
                     startpos = self._fill_coord(forcepos)