Various Laser / Spindle improvements (MarlinFirmware#15335)

Marlin/Configuration_adv.h

@@ -2662,31 +2662,123 @@
   #define SPINDLE_LASER_ACTIVE_HIGH     false  // Set to "true" if the on/off function is active HIGH
   #define SPINDLE_LASER_PWM             true   // Set to "true" if your controller supports setting the speed/power
   #define SPINDLE_LASER_PWM_INVERT      true   // Set to "true" if the speed/power goes up when you want it to go slower
-  #define SPINDLE_LASER_POWERUP_DELAY   5000   // (ms) Delay to allow the spindle/laser to come up to speed/power
-  #define SPINDLE_LASER_POWERDOWN_DELAY 5000   // (ms) Delay to allow the spindle to stop
+
+  #define SPINDLE_LASER_FREQUENCY       2500   // (Hz) Spindle/laser frequency (only on supported HALs: AVR and LPC)
+
+  /**
+   * Speed / Power can be set ('M3 S') and displayed in terms of:
+   *  - PWM     (S0 - S255)
+   *  - PERCENT (S0 - S100)
+   *  - RPM     (S0 - S50000)  Best for use with a spindle
+   */
+  #define CUTTER_POWER_DISPLAY PWM
+
+  /**
+   * Relative mode uses relative range (SPEED_POWER_MIN to SPEED_POWER_MAX) instead of normal range (0 to SPEED_POWER_MAX)
+   * Best use with SuperPID router controller where for example S0 = 5,000 RPM and S255 = 30,000 RPM
+   */
+  //#define CUTTER_POWER_RELATIVE              // Set speed proportional to [SPEED_POWER_MIN...SPEED_POWER_MAX] instead of directly
 
   #if ENABLED(SPINDLE_FEATURE)
     //#define SPINDLE_CHANGE_DIR               // Enable if your spindle controller can change spindle direction
     #define SPINDLE_CHANGE_DIR_STOP            // Enable if the spindle should stop before changing spin direction
     #define SPINDLE_INVERT_DIR          false  // Set to "true" if the spin direction is reversed
 
+    #define SPINDLE_LASER_POWERUP_DELAY   5000 // (ms) Delay to allow the spindle/laser to come up to speed/power
+    #define SPINDLE_LASER_POWERDOWN_DELAY 5000 // (ms) Delay to allow the spindle to stop
+
     /**
-     *  The M3 & M4 commands use the following equation to convert PWM duty cycle to speed/power
+     * M3/M4 uses the following equation to convert speed/power to PWM duty cycle
+     * Power = ((DC / 255 * 100) - SPEED_POWER_INTERCEPT)) * (1 / SPEED_POWER_SLOPE)
+     *   where PWM DC varies from 0 to 255
      *
-     *  SPEED/POWER = PWM duty cycle * SPEED_POWER_SLOPE + SPEED_POWER_INTERCEPT
-     *    where PWM duty cycle varies from 0 to 255
-     *
-     *  set the following for your controller (ALL MUST BE SET)
+     * Set these required parameters for your controller
      */
-    #define SPEED_POWER_SLOPE    118.4
-    #define SPEED_POWER_INTERCEPT  0
-    #define SPEED_POWER_MIN     5000
-    #define SPEED_POWER_MAX    30000    // SuperPID router controller 0 - 30,000 RPM
+    #define SPEED_POWER_SLOPE           118.4  // SPEED_POWER_SLOPE = SPEED_POWER_MAX / 255
+    #define SPEED_POWER_INTERCEPT         0
+    #define SPEED_POWER_MIN            5000
+    #define SPEED_POWER_MAX           30000    // SuperPID router controller 0 - 30,000 RPM
+    #define SPEED_POWER_STARTUP       25000    // The default value for speed power when M3 is called without arguments
+
   #else
-    #define SPEED_POWER_SLOPE      0.3922
-    #define SPEED_POWER_INTERCEPT  0
-    #define SPEED_POWER_MIN       10
-    #define SPEED_POWER_MAX      100    // 0-100%
+
+    #define SPEED_POWER_SLOPE             0.3922 // SPEED_POWER_SLOPE = SPEED_POWER_MAX / 255
+    #define SPEED_POWER_INTERCEPT         0
+    #define SPEED_POWER_MIN               0
+    #define SPEED_POWER_MAX             100    // 0-100%
+    #define SPEED_POWER_STARTUP          80    // The default value for speed power when M3 is called without arguments
+
+    /**
+     * Enable inline laser power to be handled in the planner / stepper routines.
+     * Inline power is specified by the I (inline) flag in an M3 command (e.g., M3 S20 I)
+     * or by the 'S' parameter in G0/G1/G2/G3 moves (see LASER_MOVE_POWER).
+     *
+     * This allows the laser to keep in perfect sync with the planner and removes
+     * the powerup/down delay since lasers require negligible time.
+     */
+    #define LASER_POWER_INLINE
+
+    #if ENABLED(LASER_POWER_INLINE)
+      /**
+       * Scale the laser's power in proportion to the movement rate.
+       *
+       * - Sets the entry power proportional to the entry speed over the nominal speed.
+       * - Ramps the power up every N steps to approximate the speed trapezoid.
+       * - Due to the limited power resolution this is only approximate.
+       */
+      #define LASER_POWER_INLINE_TRAPEZOID
+
+      /**
+       * Continuously calculate the current power (nominal_power * current_rate / nominal_rate).
+       * Required for accurate power with non-trapezoidal acceleration (e.g., S_CURVE_ACCELERATION).
+       * This is a costly calculation so this option is discouraged on 8-bit AVR boards.
+       *
+       * LASER_POWER_INLINE_TRAPEZOID_CONT_PER defines how many step cycles there are between power updates. If your
+       * board isn't able to generate steps fast enough (and you are using LASER_POWER_INLINE_TRAPEZOID_CONT), increase this.
+       * Note that when this is zero it means it occurs every cycle; 1 means a delay wait one cycle then run, etc.
+       */
+      //#define LASER_POWER_INLINE_TRAPEZOID_CONT
+
+      /**
+       * Stepper iterations between power updates. Increase this value if the board
+       * can't keep up with the processing demands of LASER_POWER_INLINE_TRAPEZOID_CONT.
+       * Disable (or set to 0) to recalculate power on every stepper iteration.
+       */
+      //#define LASER_POWER_INLINE_TRAPEZOID_CONT_PER 10
+
+      /**
+       * Include laser power in G0/G1/G2/G3/G5 commands with the 'S' parameter
+       */
+      //#define LASER_MOVE_POWER
+
+      #if ENABLED(LASER_MOVE_POWER)
+        // Turn off the laser on G0 moves with no power parameter.
+        // If a power parameter is provided, use that instead.
+        //#define LASER_MOVE_G0_OFF
+      #endif
+
+      /**
+       * Inline flag inverted
+       *
+       * WARNING: M5 will NOT turn off the laser unless another move
+       *          is done (so G-code files must end with 'M5 I').
+       */
+      //#define LASER_POWER_INLINE_INVERT
+
+      /**
+       * Continuously apply inline power. ('M3 S3' == 'G1 S3' == 'M3 S3 I')
+       *
+       * The laser might do some weird things, so only enable this
+       * feature if you understand the implications.
+       */
+      //#define LASER_POWER_INLINE_CONTINUOUS
+
+    #else
+
+      #define SPINDLE_LASER_POWERUP_DELAY     50 // (ms) Delay to allow the spindle/laser to come up to speed/power
+      #define SPINDLE_LASER_POWERDOWN_DELAY   50 // (ms) Delay to allow the spindle to stop
+
+    #endif
   #endif
 #endif
 

Marlin/src/HAL/AVR/HAL.h

@@ -395,6 +395,8 @@ inline void HAL_adc_init() {
 // AVR compatibility
 #define strtof strtod
 
+#define HAL_CAN_SET_PWM_FREQ   // This HAL supports PWM Frequency adjustment
+
 /**
  *  set_pwm_frequency
  *  Sets the frequency of the timer corresponding to the provided pin

Marlin/src/HAL/AVR/fast_pwm.cpp

@@ -23,7 +23,7 @@
 
 #include "../../inc/MarlinConfigPre.h"
 
-#if ENABLED(FAST_PWM_FAN) || SPINDLE_LASER_PWM
+#if NEEDS_HARDWARE_PWM // Specific meta-flag for features that mandate PWM
 
 #include "HAL.h"
 
@@ -278,5 +278,5 @@ void set_pwm_duty(const pin_t pin, const uint16_t v, const uint16_t v_size/*=255
   }
 }
 
-#endif // FAST_PWM_FAN || SPINDLE_LASER_PWM
+#endif // NEEDS_HARDWARE_PWM
 #endif // __AVR__

Marlin/src/HAL/LPC1768/HAL.h

@@ -197,6 +197,8 @@ void HAL_idletask();
 #define PLATFORM_M997_SUPPORT
 void flashFirmware(const int16_t);
 
+#define HAL_CAN_SET_PWM_FREQ   // This HAL supports PWM Frequency adjustment
+
 /**
  * set_pwm_frequency
  *  Set the frequency of the timer corresponding to the provided pin

Marlin/src/HAL/LPC1768/fast_pwm.cpp

@@ -24,7 +24,7 @@
 
 #include "../../inc/MarlinConfigPre.h"
 
-#if ENABLED(FAST_PWM_FAN) || SPINDLE_LASER_PWM
+#if NEEDS_HARDWARE_PWM // Specific meta-flag for features that mandate PWM
 
 #include <pwm.h>
 

Marlin/src/MarlinCore.cpp

@@ -420,7 +420,11 @@ void startOrResumeJob() {
     #if DISABLED(SD_ABORT_NO_COOLDOWN)
       thermalManager.disable_all_heaters();
     #endif
-    thermalManager.zero_fan_speeds();
+    #if !HAS_CUTTER
+      thermalManager.zero_fan_speeds();
+    #else
+      cutter.kill();              // Full cutter shutdown including ISR control
+    #endif
     wait_for_heatup = false;
     #if ENABLED(POWER_LOSS_RECOVERY)
       recovery.purge();
@@ -741,6 +745,10 @@ void idle(TERN_(ADVANCED_PAUSE_FEATURE, bool no_stepper_sleep/*=false*/)) {
 void kill(PGM_P const lcd_error/*=nullptr*/, PGM_P const lcd_component/*=nullptr*/, const bool steppers_off/*=false*/) {
   thermalManager.disable_all_heaters();
 
+  #if HAS_CUTTER
+    cutter.kill();              // Full cutter shutdown including ISR control
+  #endif
+
   SERIAL_ERROR_MSG(STR_ERR_KILLED);
 
   #if HAS_DISPLAY
@@ -770,6 +778,10 @@ void minkill(const bool steppers_off/*=false*/) {
   // Reiterate heaters off
   thermalManager.disable_all_heaters();
 
+  #if HAS_CUTTER
+    cutter.kill();  // Reiterate cutter shutdown
+  #endif
+
   // Power off all steppers (for M112) or just the E steppers
   steppers_off ? disable_all_steppers() : disable_e_steppers();
 
@@ -789,14 +801,14 @@ void minkill(const bool steppers_off/*=false*/) {
     // Wait for kill to be pressed
     while (READ(KILL_PIN)) watchdog_refresh();
 
-    void (*resetFunc)() = 0;  // Declare resetFunc() at address 0
+    void (*resetFunc)() = 0;      // Declare resetFunc() at address 0
     resetFunc();                  // Jump to address 0
 
-  #else // !HAS_KILL
+  #else
 
-    for (;;) watchdog_refresh(); // Wait for reset
+    for (;;) watchdog_refresh();  // Wait for reset
 
-  #endif // !HAS_KILL
+  #endif
 }
 
 /**

Marlin/src/core/drivers.h

@@ -174,15 +174,6 @@
 // Defines that can't be evaluated now
 #define HAS_TMC_SW_SERIAL ANY_AXIS_HAS(SW_SERIAL)
 
-//
-// Stretching 'drivers.h' to include LPC/SAMD51 SD options
-//
-#define _SDCARD_LCD          1
-#define _SDCARD_ONBOARD      2
-#define _SDCARD_CUSTOM_CABLE 3
-#define _SDCARD_ID(V) _CAT(_SDCARD_, V)
-#define SD_CONNECTION_IS(V) (_SDCARD_ID(SDCARD_CONNECTION) == _SDCARD_ID(V))
-
 #if HAS_DRIVER(L6470) || HAS_DRIVER(L6474) || HAS_DRIVER(L6480) || HAS_DRIVER(POWERSTEP01)
   #define HAS_L64XX 1
 #endif

Marlin/src/feature/spindle_laser.cpp

@@ -32,10 +32,17 @@
 
 SpindleLaser cutter;
 
-cutter_power_t SpindleLaser::power; // = 0
-
+cutter_power_t SpindleLaser::power;
+bool SpindleLaser::isOn;                                                       // state to determine when to apply setPower to power
+cutter_setPower_t SpindleLaser::setPower = interpret_power(SPEED_POWER_MIN);   // spindle/laser speed/power control in PWM, Percentage or RPM
+#if ENABLED(MARLIN_DEV_MODE)
+  cutter_frequency_t SpindleLaser::frequency;                                  // setting PWM frequency; range: 2K - 50K
+#endif
 #define SPINDLE_LASER_PWM_OFF ((SPINDLE_LASER_PWM_INVERT) ? 255 : 0)
 
+//
+// Init the cutter to a safe OFF state
+//
 void SpindleLaser::init() {
   OUT_WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH); // Init spindle to off
   #if ENABLED(SPINDLE_CHANGE_DIR)
@@ -45,41 +52,39 @@ void SpindleLaser::init() {
     SET_PWM(SPINDLE_LASER_PWM_PIN);
     analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF);  // set to lowest speed
   #endif
+  #if ENABLED(HAL_CAN_SET_PWM_FREQ) && defined(SPINDLE_LASER_FREQUENCY)
+    set_pwm_frequency(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_FREQUENCY);
+    #if ENABLED(MARLIN_DEV_MODE)
+      frequency = SPINDLE_LASER_FREQUENCY;
+    #endif
+  #endif
 }
 
 #if ENABLED(SPINDLE_LASER_PWM)
 
   /**
-   * ocr_val_mode() is used for debugging and to get the points needed to compute the RPM vs ocr_val line
-   *
-   * it accepts inputs of 0-255
-   */
+  * Set the cutter PWM directly to the given ocr value
+  **/
   void SpindleLaser::set_ocr(const uint8_t ocr) {
-    WRITE(SPINDLE_LASER_ENA_PIN, SPINDLE_LASER_ACTIVE_HIGH); // turn spindle on (active low)
+    WRITE(SPINDLE_LASER_ENA_PIN, SPINDLE_LASER_ACTIVE_HIGH); // turn spindle on
     analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), ocr ^ SPINDLE_LASER_PWM_OFF);
   }
 
 #endif
 
+//
+// Set cutter ON state (and PWM) to the given cutter power value
+//
 void SpindleLaser::apply_power(const cutter_power_t inpow) {
   static cutter_power_t last_power_applied = 0;
   if (inpow == last_power_applied) return;
   last_power_applied = inpow;
   #if ENABLED(SPINDLE_LASER_PWM)
-    if (enabled()) {
-      #define _scaled(F) ((F - (SPEED_POWER_INTERCEPT)) * inv_slope)
-      constexpr float inv_slope = RECIPROCAL(SPEED_POWER_SLOPE),
-                      min_ocr = _scaled(SPEED_POWER_MIN),
-                      max_ocr = _scaled(SPEED_POWER_MAX);
-      int16_t ocr_val;
-           if (inpow <= SPEED_POWER_MIN) ocr_val = min_ocr;       // Use minimum if set below
-      else if (inpow >= SPEED_POWER_MAX) ocr_val = max_ocr;       // Use maximum if set above
-      else ocr_val = _scaled(inpow);                              // Use calculated OCR value
-      set_ocr(ocr_val & 0xFF);                                    // ...limited to Atmel PWM max
-    }
+    if (enabled())
+      set_ocr(translate_power(inpow));
     else {
-      WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH);   // Turn spindle off (active low)
-      analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF);  // Only write low byte
+      WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH);                           // Turn spindle off
+      analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF);                   // Only write low byte
     }
   #else
     WRITE(SPINDLE_LASER_ENA_PIN, (SPINDLE_LASER_ACTIVE_HIGH) ? enabled() : !enabled());
@@ -88,6 +93,10 @@ void SpindleLaser::apply_power(const cutter_power_t inpow) {
 
 #if ENABLED(SPINDLE_CHANGE_DIR)
 
+  //
+  // Set the spindle direction and apply immediately
+  // Stop on direction change if SPINDLE_STOP_ON_DIR_CHANGE is enabled
+  //
   void SpindleLaser::set_direction(const bool reverse) {
     const bool dir_state = (reverse == SPINDLE_INVERT_DIR); // Forward (M3) HIGH when not inverted
     #if ENABLED(SPINDLE_STOP_ON_DIR_CHANGE)