/* stepper.c - stepper motor driver: executes motion plans using stepper motors Part of Grbl Copyright (c) 2011-2013 Sungeun K. Jeon Copyright (c) 2009-2011 Simen Svale Skogsrud Grbl 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. Grbl 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. You should have received a copy of the GNU General Public License along with Grbl. If not, see . */ #include #include "stepper.h" #include "config.h" #include "settings.h" #include "planner.h" #include "nuts_bolts.h" // Some useful constants. #define TICKS_PER_MICROSECOND (F_CPU/1000000) #define DT_SEGMENT (1.0/(ACCELERATION_TICKS_PER_SECOND*60.0)) // min/segment #define STEP_FTOL_MULTIPLIER 100000 // Multiplier converts floating point step rate to long // integer for stepper algorithm step-distance counter. #define RAMP_ACCEL 0 #define RAMP_CRUISE 1 #define RAMP_DECEL 2 // Stores the planner block Bresenham algorithm execution data for the segments in the segment // buffer. Normally, this buffer is partially in-use, but, for the worst case scenario, it will // never exceed the number of accessible stepper buffer segments (SEGMENT_BUFFER_SIZE-1). // NOTE: This data is copied from the prepped planner blocks so that the planner blocks may be // discarded when entirely consumed and completed by the segment buffer. typedef struct { uint8_t direction_bits; int32_t steps[N_AXIS]; int32_t step_event_count; } st_block_t; static st_block_t st_block_buffer[SEGMENT_BUFFER_SIZE-1]; // TODO: Directly adjust this parameters to stop motion of individual axes for the homing cycle. // But this may require this to be volatile if it is controlled by an interrupt. // Primary stepper segment ring buffer. Contains small, short line segments for the stepper // algorithm to execute, which are "checked-out" incrementally from the first block in the // planner buffer. Once "checked-out", the steps in the segments buffer cannot be modified by // the planner, where the remaining planner block steps still can. typedef struct { uint8_t n_step; // Number of step events to be executed for this segment uint8_t st_block_index; // Stepper block data index. Uses this information to execute this segment. int32_t phase_dist; // Remaining step fraction to tick before completing segment. int32_t dist_per_tick; // Step distance traveled per ISR tick, aka step rate. } segment_t; static segment_t segment_buffer[SEGMENT_BUFFER_SIZE]; // Stepper state variable. Contains running data and trapezoid variables. typedef struct { // Used by the bresenham line algorithm int32_t counter_x, // Counter variables for the bresenham line tracer counter_y, counter_z; // Used by inverse time algorithm to track step rate int32_t counter_dist; // Inverse time distance traveled since last step event // Used by the stepper driver interrupt uint8_t execute_step; // Flags step execution for each interrupt. uint8_t step_pulse_time; // Step pulse reset time after step rise uint8_t out_bits; // The next stepping-bits to be output uint8_t step_count; // Steps remaining in line segment motion uint8_t exec_block_index; // Tracks the current st_block index. Change indicates new block. st_block_t *exec_block; // Pointer to the block data for the segment being executed segment_t *exec_segment; // Pointer to the segment being executed } stepper_t; static stepper_t st; // Step segment ring buffer indices static volatile uint8_t segment_buffer_tail; static uint8_t segment_buffer_head; static uint8_t segment_next_head; // Used to avoid ISR nesting of the "Stepper Driver Interrupt". Should never occur though. static volatile uint8_t busy; // Pointers for the step segment being prepped from the planner buffer. Accessed only by the // main program. Pointers may be planning segments or planner blocks ahead of what being executed. static plan_block_t *pl_block; // Pointer to the planner block being prepped static st_block_t *st_prep_block; // Pointer to the stepper block data being prepped // Segment preparation data struct. Contains all the necessary information to compute new segments // based on the current executing planner block. typedef struct { uint8_t st_block_index; // Index of stepper common data block being prepped uint8_t flag_partial_block; // Flag indicating the last block completed. Time to load a new one. float step_per_mm; // Current planner block step/millimeter conversion scalar float steps_remaining; uint8_t ramp_type; // Current segment ramp state float mm_complete; // End of velocity profile from end of current planner block in (mm). float current_speed; // Current speed at the end of the segment buffer (mm/min) float maximum_speed; // Maximum speed of executing block. Not always nominal speed. (mm/min) 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) } st_prep_t; static st_prep_t prep; /* BLOCK VELOCITY PROFILE DEFINITION __________________________ /| |\ _________________ ^ / | | \ /| |\ | / | | \ / | | \ s / | | | | | \ p / | | | | | \ e +-----+------------------------+---+--+---------------+----+ e | BLOCK 1 ^ BLOCK 2 | d | time -----> EXAMPLE: Block 2 entry speed is at max junction velocity The planner block buffer is planned assuming constant acceleration velocity profiles and are continuously joined at block junctions as shown above. However, the planner only actively computes the block entry speeds for an optimal velocity plan, but does not compute the block internal velocity profiles. These velocity profiles are computed ad-hoc as they are executed by the stepper algorithm and consists of only 7 possible types of profiles: cruise-only, cruise- deceleration, acceleration-cruise, acceleration-only, deceleration-only, full-trapezoid, and triangle(no cruise). maximum_speed (< nominal_speed) -> + +--------+ <- maximum_speed (= nominal_speed) /|\ / \ / | \ current_speed -> + \ / | + <- exit_speed | + <- exit_speed / | | +-------------+ current_speed -> +----+--+ time --> ^ ^ ^ ^ | | | | decelerate_after(in mm) decelerate_after(in mm) ^ ^ ^ ^ | | | | accelerate_until(in mm) accelerate_until(in mm) The step segment buffer computes the executing block velocity profile and tracks the critical parameters for the stepper algorithm to accurately trace the profile. These critical parameters are shown and defined in the above illustration. */ // Stepper state initialization. Cycle should only start if the st.cycle_start flag is // enabled. Startup init and limits call this function but shouldn't start the cycle. void st_wake_up() { // Enable steppers by resetting the stepper disable port if (bit_istrue(settings.flags,BITFLAG_INVERT_ST_ENABLE)) { STEPPERS_DISABLE_PORT |= (1<> 3); // Enable stepper driver interrupt TCNT2 = 0; // Clear Timer2 TIMSK2 |= (1<n_step; // If the new segment starts a new planner block, initialize stepper variables and counters. // NOTE: When the segment data index changes, this indicates a new planner block. if ( st.exec_block_index != st.exec_segment->st_block_index ) { st.exec_block_index = st.exec_segment->st_block_index; st.exec_block = &st_block_buffer[st.exec_block_index]; // Initialize direction bits for block. Set execute flag to set directions bits upon next ISR tick. st.out_bits = st.exec_block->direction_bits ^ settings.invert_mask; st.execute_step = true; // Initialize Bresenham line and distance counters st.counter_x = (st.exec_block->step_event_count >> 1); st.counter_y = st.counter_x; st.counter_z = st.counter_x; st.counter_dist = 0; } } else { // Segment buffer empty. Shutdown. st_go_idle(); bit_true(sys.execute,EXEC_CYCLE_STOP); // Flag main program for cycle end return; // Nothing to do but exit. } } // Iterate inverse time counter. Triggers each Bresenham step event. st.counter_dist += st.exec_segment->dist_per_tick; // Execute Bresenham step event, when it's time to do so. if (st.counter_dist > STEP_FTOL_MULTIPLIER) { if (st.step_count > 0) { // Block phase correction from executing step. st.counter_dist -= STEP_FTOL_MULTIPLIER; // Reload inverse time counter st.step_count--; // Decrement step events count // Execute step displacement profile by Bresenham line algorithm st.execute_step = true; st.out_bits = st.exec_block->direction_bits; // Reset out_bits and reload direction bits st.counter_x -= st.exec_block->steps[X_AXIS]; if (st.counter_x < 0) { st.out_bits |= (1<step_event_count; if (st.out_bits & (1<steps[Y_AXIS]; if (st.counter_y < 0) { st.out_bits |= (1<step_event_count; if (st.out_bits & (1<steps[Z_AXIS]; if (st.counter_z < 0) { st.out_bits |= (1<step_event_count; if (st.out_bits & (1< st.exec_segment->phase_dist) { // Segment is complete. Discard current segment and advance segment indexing. st.exec_segment = NULL; if ( ++segment_buffer_tail == SEGMENT_BUFFER_SIZE) { segment_buffer_tail = 0; } } } busy = false; // SPINDLE_ENABLE_PORT ^= 1<entry_speed_sqr = prep.current_speed*prep.current_speed; // Update entry speed. pl_block = NULL; // Flag st_prep_segment() to load new velocity profile. } } /* Prepares step segment buffer. Continuously called from main program. The segment buffer is an intermediary buffer interface between the execution of steps by the stepper algorithm and the velocity profiles generated by the planner. The stepper algorithm only executes steps within the segment buffer and is filled by the main program when steps are "checked-out" from the first block in the planner buffer. This keeps the step execution and planning optimization processes atomic and protected from each other. The number of steps "checked-out" from the planner buffer and the number of segments in the segment buffer is sized and computed such that no operation in the main program takes longer than the time it takes the stepper algorithm to empty it before refilling it. Currently, the segment buffer conservatively holds roughly up to 40-50 msec of steps. NOTE: The segment buffer executes a computed number of steps over a configured segment execution time period, except at an end of a planner block where the segment execution gets truncated by the lack of travel distance. Since steps are integer values and to keep the distance traveled over the segment exact, a fractional step remaining after the last executed step in a segment is handled by allowing the stepper algorithm distance counters to tick to this fractional value without triggering a full step. So, when the next segment is loaded for execution, its first full step will already have the distance counters primed with the previous segment fractional step and will execute exactly on time according to the planner block velocity profile. This ensures the step phasing between segments are kept in sync and prevents artificially created accelerations between segments if they are not accounted for. This allows the stepper algorithm to run at very high step rates without losing steps. */ void st_prep_buffer() { if (sys.state == STATE_QUEUED) { return; } // Block until a motion state is issued while (segment_buffer_tail != segment_next_head) { // Check if we need to fill the buffer. // Determine if we need to load a new planner block or if the block remainder is replanned. if (pl_block == NULL) { pl_block = plan_get_current_block(); // Query planner for a queued block if (pl_block == NULL) { return; } // No planner blocks. Exit. // Check if the segment buffer completed the last planner block. If so, load the Bresenham // data for the block. If not, we are still mid-block and the velocity profile has changed. if (prep.flag_partial_block) { prep.flag_partial_block = false; // Reset flag } else { // Increment stepper common data index if ( ++prep.st_block_index == (SEGMENT_BUFFER_SIZE-1) ) { prep.st_block_index = 0; } // Prepare and copy Bresenham algorithm segment data from the new planner block, so that // when the segment buffer completes the planner block, it may be discarded immediately. st_prep_block = &st_block_buffer[prep.st_block_index]; st_prep_block->steps[X_AXIS] = pl_block->steps[X_AXIS]; st_prep_block->steps[Y_AXIS] = pl_block->steps[Y_AXIS]; st_prep_block->steps[Z_AXIS] = pl_block->steps[Z_AXIS]; st_prep_block->direction_bits = pl_block->direction_bits; st_prep_block->step_event_count = pl_block->step_event_count; // Initialize segment buffer data for generating the segments. prep.steps_remaining = st_prep_block->step_event_count; prep.step_per_mm = prep.steps_remaining/pl_block->millimeters; if (sys.state == STATE_HOLD) { // Override planner block entry speed and enforce deceleration during feed hold. prep.current_speed = prep.exit_speed; pl_block->entry_speed_sqr = prep.exit_speed*prep.exit_speed; } else { prep.current_speed = sqrt(pl_block->entry_speed_sqr); } } /* --------------------------------------------------------------------------------- Compute the velocity profile of a new planner block based on its entry and exit speeds, or recompute the profile of a partially-completed planner block if the planner has updated it. For a commanded forced-deceleration, such as from a feed hold, override the planner velocities and decelerate to the target exit speed. */ prep.mm_complete = 0.0; // Default velocity profile complete at 0.0mm from end of block. float inv_2_accel = 0.5/pl_block->acceleration; if (sys.state == STATE_HOLD) { // Compute velocity profile parameters for a feed hold in-progress. This profile overrides // the planner block profile, enforcing a deceleration to zero speed. prep.ramp_type = RAMP_DECEL; float decel_dist = inv_2_accel*pl_block->entry_speed_sqr; if (decel_dist < pl_block->millimeters) { prep.exit_speed = 0.0; prep.mm_complete = pl_block->millimeters-decel_dist; // End of feed hold. } else { prep.exit_speed = sqrt(pl_block->entry_speed_sqr-2*pl_block->acceleration*pl_block->millimeters); } } else { // Compute or recompute velocity profile parameters of the prepped planner block. prep.ramp_type = RAMP_ACCEL; // Initialize as acceleration ramp. prep.accelerate_until = pl_block->millimeters; prep.exit_speed = plan_get_exec_block_exit_speed(); float exit_speed_sqr = prep.exit_speed*prep.exit_speed; float intersect_distance = 0.5*(pl_block->millimeters+inv_2_accel*(pl_block->entry_speed_sqr-exit_speed_sqr)); if (intersect_distance > 0.0) { if (intersect_distance < pl_block->millimeters) { // Either trapezoid or triangle types // NOTE: For acceleration-cruise and cruise-only types, following calculation will be 0.0. prep.decelerate_after = inv_2_accel*(pl_block->nominal_speed_sqr-exit_speed_sqr); if (prep.decelerate_after < intersect_distance) { // Trapezoid type prep.maximum_speed = sqrt(pl_block->nominal_speed_sqr); if (pl_block->entry_speed_sqr == pl_block->nominal_speed_sqr) { // Cruise-deceleration or cruise-only type. prep.ramp_type = RAMP_CRUISE; } else { // Full-trapezoid or acceleration-cruise types prep.accelerate_until -= inv_2_accel*(pl_block->nominal_speed_sqr-pl_block->entry_speed_sqr); } } else { // Triangle type prep.accelerate_until = intersect_distance; prep.decelerate_after = intersect_distance; prep.maximum_speed = sqrt(2.0*pl_block->acceleration*intersect_distance+exit_speed_sqr); } } else { // Deceleration-only type prep.ramp_type = RAMP_DECEL; // prep.decelerate_after = pl_block->millimeters; prep.maximum_speed = prep.current_speed; } } else { // Acceleration-only type prep.accelerate_until = 0.0; // prep.decelerate_after = 0.0; prep.maximum_speed = prep.exit_speed; } } } // Initialize new segment segment_t *prep_segment = &segment_buffer[segment_buffer_head]; // Set new segment to point to the current segment data block. prep_segment->st_block_index = prep.st_block_index; /*------------------------------------------------------------------------------------ Compute the average velocity of this new segment by determining the total distance traveled over the segment time DT_SEGMENT. The following code first attempts to create a full segment based on the current ramp conditions. If the segment time is incomplete when terminating at a ramp state change, the code will continue to loop through the progressing ramp states to fill the remaining segment execution time. However, if an incomplete segment terminates at the end of the velocity profile, the segment is considered completed despite having a truncated execution time less than DT_SEGMENT. The velocity profile is always assumed to progress through the ramp sequence: acceleration ramp, cruising state, and deceleration ramp. Each ramp's travel distance may range from zero to the length of the block. Velocity profiles can end either at the end of planner block (typical) or mid-block at the end of a forced deceleration, such as from a feed hold. */ float dt = 0.0; float mm_remaining = pl_block->millimeters; float time_var = DT_SEGMENT; // Time worker variable float mm_var; // mm-Distance worker variable float speed_var; // Speed work variable. do { switch (prep.ramp_type) { case RAMP_ACCEL: // NOTE: Acceleration ramp only computes during first do-while loop. speed_var = pl_block->acceleration*DT_SEGMENT; mm_remaining -= DT_SEGMENT*(prep.current_speed + 0.5*speed_var); if (mm_remaining < prep.accelerate_until) { // End of acceleration ramp. // Acceleration-cruise, acceleration-deceleration ramp junction, or end of block. mm_remaining = prep.accelerate_until; // NOTE: 0.0 at EOB time_var = 2.0*(pl_block->millimeters-mm_remaining)/(prep.current_speed+prep.maximum_speed); if (mm_remaining == prep.decelerate_after) { prep.ramp_type = RAMP_DECEL; } else { prep.ramp_type = RAMP_CRUISE; } prep.current_speed = prep.maximum_speed; } else { // Acceleration only. prep.current_speed += speed_var; } break; case RAMP_CRUISE: // NOTE: mm_var used to retain the last mm_remaining for incomplete segment time_var calculations. mm_var = mm_remaining - prep.maximum_speed*time_var; if (mm_var < prep.decelerate_after) { // End of cruise. // Cruise-deceleration junction or end of block. time_var = (mm_remaining - prep.decelerate_after)/prep.maximum_speed; mm_remaining = prep.decelerate_after; // NOTE: 0.0 at EOB prep.ramp_type = RAMP_DECEL; } else { // Cruising only. mm_remaining = mm_var; } break; default: // case RAMP_DECEL: // NOTE: mm_var used as a misc worker variable to prevent errors when near zero speed. speed_var = pl_block->acceleration*time_var; // Used as delta speed (mm/min) if (prep.current_speed > speed_var) { // Check if at or below zero speed. // Compute distance from end of segment to end of block. mm_var = mm_remaining - time_var*(prep.current_speed - 0.5*speed_var); // (mm) if (mm_var > prep.mm_complete) { // Deceleration only. mm_remaining = mm_var; prep.current_speed -= speed_var; break; // Segment complete. Exit switch-case statement. } } // End of block or end of forced-deceleration. time_var = 2.0*(mm_remaining-prep.mm_complete)/(prep.current_speed+prep.exit_speed); mm_remaining = prep.mm_complete; } dt += time_var; // Add computed ramp time to total segment time. if (dt < DT_SEGMENT) { time_var = DT_SEGMENT - dt; } // **Incomplete** At ramp junction. else { break; } // **Complete** Exit loop. Segment execution time maxed. } while (mm_remaining > prep.mm_complete); // **Complete** Exit loop. Profile complete. /* ----------------------------------------------------------------------------------- Compute segment step rate, steps to execute, and step phase correction parameters. NOTE: Steps are computed by direct scalar conversion of the millimeter distance remaining in the block, rather than incrementally tallying the steps executed per segment. This helps in removing floating point round-off issues of several additions. However, since floats have only 7.2 significant digits, long moves with extremely high step counts can exceed the precision of floats, which can lead to lost steps. Fortunately, this scenario is highly unlikely and unrealistic in CNC machines supported by Grbl (i.e. exceeding 10 meters axis travel at 200 step/mm). */ // Use time_var to pre-compute dt inversion with integer multiplier. time_var = (STEP_FTOL_MULTIPLIER/(60.0*ISR_TICKS_PER_SECOND))/dt; // (ftol_mult/isr_tic) if (mm_remaining > 0.0) { // Block still incomplete. Distance remaining to be executed. float steps_remaining = prep.step_per_mm*mm_remaining; prep_segment->dist_per_tick = ceil( (prep.steps_remaining-steps_remaining)*time_var ); // (ftol_mult*step/isr_tic) // Compute number of steps to execute and segment step phase correction. prep_segment->phase_dist = ceil(STEP_FTOL_MULTIPLIER*(ceil(steps_remaining)-steps_remaining)); prep_segment->n_step = ceil(prep.steps_remaining)-ceil(steps_remaining); // Update step execution variables. if (mm_remaining == prep.mm_complete) { // NOTE: Currently only feed holds qualify for this scenario. May change with overrides. prep.current_speed = 0.0; prep.steps_remaining = ceil(steps_remaining); pl_block->millimeters = prep.steps_remaining/prep.step_per_mm; // Update with full steps. plan_cycle_reinitialize(); sys.state = STATE_QUEUED; // End cycle. } else { pl_block->millimeters = mm_remaining; prep.steps_remaining = steps_remaining; } } else { // End of block. // Set to execute the remaining steps and no phase correction upon finishing the block. prep_segment->dist_per_tick = ceil( prep.steps_remaining*time_var ); // (mult*step/isr_tic) prep_segment->phase_dist = 0; prep_segment->n_step = ceil(prep.steps_remaining); // The planner block is complete. All steps are set to be executed in the segment buffer. // TODO: Broken with feed holds. Need to recalculate the planner buffer at this time. pl_block = NULL; plan_discard_current_block(); if (sys.state == STATE_HOLD) { if (prep.current_speed == 0.0) { plan_cycle_reinitialize(); sys.state = STATE_QUEUED; } } } // New step segment initialization completed. Increment segment buffer indices. segment_buffer_head = segment_next_head; if ( ++segment_next_head == SEGMENT_BUFFER_SIZE ) { segment_next_head = 0; } // int32_t blength = segment_buffer_head - segment_buffer_tail; // if (blength < 0) { blength += SEGMENT_BUFFER_SIZE; } // printInteger(blength); if ((sys.state == STATE_HOMING) || (sys.state == STATE_QUEUED)) { return; } // Force only one prepped segment. } } /* TODO: With feedrate overrides, increases to the override value will not significantly change the current planner and stepper operation. When the value increases, we simply need to recompute the block plan with new nominal speeds and maximum junction velocities. However with a decreasing feedrate override, this gets a little tricky. The current block plan is optimal, so if we try to reduce the feed rates, it may be impossible to create a feasible plan at its current operating speed and decelerate down to zero at the end of the buffer. We first have to enforce a deceleration to meet and intersect with the reduced feedrate override plan. For example, if the current block is cruising at a nominal rate and the feedrate override is reduced, the new nominal rate will now be lower. The velocity profile must first decelerate to the new nominal rate and then follow on the new plan. Another issue is whether or not a feedrate override reduction causes a deceleration that acts over several planner blocks. For example, say that the plan is already heavily decelerating throughout it, reducing the feedrate override will not do much to it. So, how do we determine when to resume the new plan? One solution is to tie into the feed hold handling code to enforce a deceleration, but check when the current speed is less than or equal to the block maximum speed and is in an acceleration or cruising ramp. At this point, we know that we can recompute the block velocity profile to meet and continue onto the new block plan. One "easy" way to do this is to have the step segment buffer enforce a deceleration and continually re-plan the planner buffer until the plan becomes feasible. This can work and may be easy to implement, but it expends a lot of CPU cycles and may block out the rest of the functions from operating at peak efficiency. Still the question is how do we know when the plan is feasible in the context of what's already in the code and not require too much more code? */