ManuelW/grbl-LPC-CoreXY
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Spindle speed overrides behavior tweak. New experimental laser dynamic power mode.

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- Spindle speed overrides now update immediately if they are changed
while in a HOLD state. Previously, they would update after exiting the
HOLD, which isn’t correct.

- New experimental dynamic laser power mode that adjusts laser power
based on current machine speed. Enabled by uncommenting
LASER_CONSTANT_POWER_PER_RATE in config.h

  - It assumes the programmed rate is the intended power/rate for the
motion.
  - Feed rate overrides (FRO) do not effect the power/rate. Meaning
that spindle PWM will automatically lower with lower FRO and increase
with higher FRO to keep it the same.
  - Spindle speed overrides (SSO) will directly increase and decrease
the power/rate. So 150% SSO will increase the PWM output by 150% for
the same speed.
  - The combination of FRO and SSO behaviors should allow for subtle
and highly flexible tuning of how the laser cutter is operating in
real-time and during the job.

- Re-factored planner block rapid rate handling for the dynamic laser
power feature. Should have had no effect on how Grbl operates.
This commit is contained in:
Sonny Jeon 2016-10-27 09:11:59 -06:00
parent cb916a996a
commit e8b717604b
8 changed files with 108 additions and 50 deletions
Show Stats Download Patch File Download Diff File Expand all files Collapse all files

16
doc/log/commit_log_v1.1.txt
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@ -1,3 +1,19 @@
----------------
Date: 2016-10-26
Author: Sonny Jeon
Subject: Add high-frequency spindle output option. Minor parking motion re-factoring.
- Some laser controllers were reported to need a very high PWM
frequency. Added a line to enable this in cpu_map.h, if needed.
- Cleaned up some of the parking code. Mostly just editing the comments.
- Moved the accessory state resetting after the initial parking
retract. Should ensure the accessory state is properly handled upon an
aborted parking restore. Not certain if this was a problem before
though. Just to be sure.
----------------
Date: 2016-10-25
Author: chamnit

5
grbl/config.h
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@ -570,6 +570,11 @@
#define PARKING_PULLOUT_INCREMENT 5.0 // Spindle pull-out and plunge distance in mm. Incremental distance.
// Must be positive value or equal to zero.
// Experimental feature that adjusts laser power (PWM output) based on current running speed of the
// machine. When laser mode is enabled, Grbl will turn off the spindle PWM pin whenever it is not
// moving, which may be confusing to some users to why their laser is not on. This behavior may change
// in future iterations of this feature, where it will turn on to the minimum rpm value when active.
// #define LASER_CONSTANT_POWER_PER_RATE
/* ---------------------------------------------------------------------------------------
OEM Single File Configuration Option

2
grbl/grbl.h
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@ -23,7 +23,7 @@
// Grbl versioning system
#define GRBL_VERSION "1.1d"
#define GRBL_VERSION_BUILD "20161026"
#define GRBL_VERSION_BUILD "20161027"
// Define standard libraries used by Grbl.
#include <avr/io.h>

16
grbl/planner.c
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@ -258,12 +258,9 @@ uint8_t plan_check_full_buffer()
// NOTE: All system motion commands, such as homing/parking, are not subject to overrides.
float plan_compute_profile_nominal_speed(plan_block_t *block)
{
float nominal_speed;
if (block->condition & PL_COND_FLAG_RAPID_MOTION) {
nominal_speed = block->rapid_rate;
nominal_speed *= (0.01*sys.r_override);
} else {
nominal_speed = block->programmed_rate;
float nominal_speed = block->programmed_rate;
if (block->condition & PL_COND_FLAG_RAPID_MOTION) { nominal_speed *= (0.01*sys.r_override); }
else {
if (!(block->condition & PL_COND_FLAG_NO_FEED_OVERRIDE)) { nominal_speed *= (0.01*sys.f_override); }
if (nominal_speed > block->rapid_rate) { nominal_speed = block->rapid_rate; }
}
@ -385,8 +382,11 @@ uint8_t plan_buffer_line(float *target, plan_line_data_t *pl_data)
block->rapid_rate = limit_value_by_axis_maximum(settings.max_rate, unit_vec);
// Store programmed rate.
block->programmed_rate = pl_data->feed_rate;
if (block->condition & PL_COND_FLAG_INVERSE_TIME) { block->programmed_rate *= block->millimeters; }
if (block->condition & PL_COND_FLAG_RAPID_MOTION) { block->programmed_rate = block->rapid_rate; }
else {
block->programmed_rate = pl_data->feed_rate;
if (block->condition & PL_COND_FLAG_INVERSE_TIME) { block->programmed_rate *= block->millimeters; }
}
// TODO: Need to check this method handling zero junction speeds when starting from rest.
if ((block_buffer_head == block_buffer_tail) || (block->condition & PL_COND_FLAG_SYSTEM_MOTION)) {

1
grbl/planner.h
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@ -45,6 +45,7 @@
#define PL_COND_FLAG_SPINDLE_CCW bit(5)
#define PL_COND_FLAG_COOLANT_FLOOD bit(6)
#define PL_COND_FLAG_COOLANT_MIST bit(7)
#define PL_COND_MOTION_MASK (PL_COND_FLAG_RAPID_MOTION|PL_COND_FLAG_SYSTEM_MOTION|PL_COND_FLAG_NO_FEED_OVERRIDE)
#define PL_COND_ACCESSORY_MASK (PL_COND_FLAG_SPINDLE_CW|PL_COND_FLAG_SPINDLE_CCW|PL_COND_FLAG_COOLANT_FLOOD|PL_COND_FLAG_COOLANT_MIST)

53
grbl/protocol.c
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@ -698,32 +698,39 @@ static void protocol_exec_rt_suspend()
// Feed hold manager. Controls spindle stop override states.
// NOTE: Hold ensured as completed by condition check at the beginning of suspend routine.
if (sys.spindle_stop_ovr & SPINDLE_STOP_OVR_INITIATE) { // Handles beginning of spindle stop
if (gc_state.modal.spindle != SPINDLE_DISABLE) {
spindle_set_state(SPINDLE_DISABLE,0.0); // De-energize
sys.spindle_stop_ovr = SPINDLE_STOP_OVR_ENABLED; // Set stop override state to enabled, if de-energized.
} else {
if (sys.spindle_stop_ovr) {
// Handles beginning of spindle stop
if (sys.spindle_stop_ovr & SPINDLE_STOP_OVR_INITIATE) {
if (gc_state.modal.spindle != SPINDLE_DISABLE) {
spindle_set_state(SPINDLE_DISABLE,0.0); // De-energize
sys.spindle_stop_ovr = SPINDLE_STOP_OVR_ENABLED; // Set stop override state to enabled, if de-energized.
} else {
sys.spindle_stop_ovr = SPINDLE_STOP_OVR_DISABLED; // Clear stop override state
}
// Handles restoring of spindle state
} else if (sys.spindle_stop_ovr & (SPINDLE_STOP_OVR_RESTORE | SPINDLE_STOP_OVR_RESTORE_CYCLE)) {
if (gc_state.modal.spindle != SPINDLE_DISABLE) {
report_feedback_message(MESSAGE_SPINDLE_RESTORE);
if (bit_istrue(settings.flags,BITFLAG_LASER_MODE)) {
// When in laser mode, ignore spindle spin-up delay. Set to turn on laser when cycle starts.
bit_true(sys.step_control, STEP_CONTROL_UPDATE_SPINDLE_PWM);
} else {
spindle_set_state((restore_condition & (PL_COND_FLAG_SPINDLE_CW | PL_COND_FLAG_SPINDLE_CCW)), restore_spindle_speed);
delay_sec(SAFETY_DOOR_SPINDLE_DELAY, DELAY_MODE_SYS_SUSPEND);
}
}
if (sys.spindle_stop_ovr & SPINDLE_STOP_OVR_RESTORE_CYCLE) {
system_set_exec_state_flag(EXEC_CYCLE_START); // Set to resume program.
}
sys.spindle_stop_ovr = SPINDLE_STOP_OVR_DISABLED; // Clear stop override state
}
} else if (sys.spindle_stop_ovr & (SPINDLE_STOP_OVR_RESTORE | SPINDLE_STOP_OVR_RESTORE_CYCLE)) { // Handles restoring of spindle state
if (gc_state.modal.spindle != SPINDLE_DISABLE) {
report_feedback_message(MESSAGE_SPINDLE_RESTORE);
if (bit_istrue(settings.flags,BITFLAG_LASER_MODE)) {
// When in laser mode, ignore spindle spin-up delay. Set to turn on laser when cycle starts.
bit_true(sys.step_control, STEP_CONTROL_UPDATE_SPINDLE_PWM);
} else {
spindle_set_state((restore_condition & (PL_COND_FLAG_SPINDLE_CW | PL_COND_FLAG_SPINDLE_CCW)), restore_spindle_speed);
delay_sec(SAFETY_DOOR_SPINDLE_DELAY, DELAY_MODE_SYS_SUSPEND);
}
} else {
// Handles spindle state during hold. NOTE: Spindle speed overrides may be altered during hold state.
// NOTE: STEP_CONTROL_UPDATE_SPINDLE_PWM is automatically reset upon resume in step generator.
if (bit_istrue(sys.step_control, STEP_CONTROL_UPDATE_SPINDLE_PWM)) {
spindle_set_state((restore_condition & (PL_COND_FLAG_SPINDLE_CW | PL_COND_FLAG_SPINDLE_CCW)), restore_spindle_speed);
bit_false(sys.step_control, STEP_CONTROL_UPDATE_SPINDLE_PWM);
}
if (sys.spindle_stop_ovr & SPINDLE_STOP_OVR_RESTORE_CYCLE) {
system_set_exec_state_flag(EXEC_CYCLE_START); // Set to resume program.
}
sys.spindle_stop_ovr = SPINDLE_STOP_OVR_DISABLED; // Clear stop override state
}
}

6
grbl/spindle_control.c
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@ -154,7 +154,7 @@ void spindle_stop()
// Compute intermediate PWM value with linear spindle speed model.
// NOTE: A nonlinear model could be installed here, if required, but keep it light-weight.
sys.spindle_speed = rpm;
pwm_value = floor( (rpm-settings.rpm_min)*pwm_gradient + (SPINDLE_PWM_MIN_VALUE+0.5));
pwm_value = floor( (rpm-settings.rpm_min)*pwm_gradient + (SPINDLE_PWM_MIN_VALUE+0.5) );
}
return(pwm_value);
}
@ -189,6 +189,10 @@ void spindle_stop()
#endif
#ifdef VARIABLE_SPINDLE
#ifdef LASER_CONSTANT_POWER_PER_RATE
// NOTE: Assumes all calls to this function is when Grbl is not moving or must remain off.
if (settings.flags & BITFLAG_LASER_MODE) { rpm = 0.0; } // TODO: May need to be rpm_min*(100/MAX_SPINDLE_SPEED_OVERRIDE);
#endif
spindle_set_speed(spindle_compute_pwm_value(rpm));
#else
// NOTE: Without variable spindle, the enable bit should just turn on or off, regardless

57
grbl/stepper.c
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@ -151,6 +151,10 @@ typedef struct {
float exit_speed; // Exit speed of executing block (mm/min)
float accelerate_until; // Acceleration ramp end measured from end of block (mm)
float decelerate_after; // Deceleration ramp start measured from end of block (mm)
#ifdef LASER_CONSTANT_POWER_PER_RATE
float inv_rate; // Used by PWM laser mode
#endif
} st_prep_t;
static st_prep_t prep;
@ -644,6 +648,11 @@ void st_prep_buffer()
} else {
prep.current_speed = sqrt(pl_block->entry_speed_sqr);
}
#ifdef LASER_CONSTANT_POWER_PER_RATE
// Pre-compute inverse programmed rate to speed up PWM updating per step segment.
prep.inv_rate = 1.0/pl_block->programmed_rate;
#endif
}
/* ---------------------------------------------------------------------------------
@ -742,19 +751,6 @@ void st_prep_buffer()
#endif
}
#ifdef VARIABLE_SPINDLE
if (sys.step_control & STEP_CONTROL_UPDATE_SPINDLE_PWM) {
// Configure correct spindle PWM state for block. Updates with planner changes and spindle speed overrides.
if (pl_block->condition & (PL_COND_FLAG_SPINDLE_CW | PL_COND_FLAG_SPINDLE_CCW)) {
st_prep_block->spindle_pwm = spindle_compute_pwm_value(pl_block->spindle_speed);
} else {
sys.spindle_speed = 0.0;
st_prep_block->spindle_pwm = SPINDLE_PWM_OFF_VALUE;
}
bit_false(sys.step_control,STEP_CONTROL_UPDATE_SPINDLE_PWM);
}
#endif
// Initialize new segment
segment_t *prep_segment = &segment_buffer[segment_buffer_head];
@ -860,6 +856,35 @@ void st_prep_buffer()
}
} while (mm_remaining > prep.mm_complete); // **Complete** Exit loop. Profile complete.
/* -----------------------------------------------------------------------------------
Compute spindle speed PWM output for step segment
*/
#ifdef VARIABLE_SPINDLE
#ifdef LASER_CONSTANT_POWER_PER_RATE
if ((settings.flags & BITFLAG_LASER_MODE) || (sys.step_control & STEP_CONTROL_UPDATE_SPINDLE_PWM)) {
#else
if (sys.step_control & STEP_CONTROL_UPDATE_SPINDLE_PWM) {
#endif
if (pl_block->condition & (PL_COND_FLAG_SPINDLE_CW | PL_COND_FLAG_SPINDLE_CCW)) {
float rpm = pl_block->spindle_speed;
#ifdef LASER_CONSTANT_POWER_PER_RATE
// NOTE: Feed and rapid overrides are independent of PWM value and do not alter laser power/rate.
if (settings.flags & BITFLAG_LASER_MODE) {
// If current_speed is zero, then may need to be rpm_min*(100/MAX_SPINDLE_SPEED_OVERRIDE)
// but this would be instantaneous only and during a motion. May not matter at all.
rpm *= (prep.current_speed * prep.inv_rate);
}
#endif
st_prep_block->spindle_pwm = spindle_compute_pwm_value(rpm);
} else {
sys.spindle_speed = 0.0;
st_prep_block->spindle_pwm = SPINDLE_PWM_OFF_VALUE;
}
bit_false(sys.step_control,STEP_CONTROL_UPDATE_SPINDLE_PWM);
}
#endif
/* -----------------------------------------------------------------------------------
Compute segment step rate, steps to execute, and apply necessary rate corrections.
@ -976,8 +1001,8 @@ void st_prep_buffer()
// divided by the ACCELERATION TICKS PER SECOND in seconds.
float st_get_realtime_rate()
{
if (sys.state & (STATE_CYCLE | STATE_HOMING | STATE_HOLD | STATE_JOG | STATE_SAFETY_DOOR)){
return prep.current_speed;
}
if (sys.state & (STATE_CYCLE | STATE_HOMING | STATE_HOLD | STATE_JOG | STATE_SAFETY_DOOR)){
return prep.current_speed;
}
return 0.0f;
}