Fix, improve Power Loss Recovery (#13703)

- Save and restore workspace offsets
- Add retract and purge (hidden) options
- Always restore axis relative modes
- Use added `G92.9` to do position restores

Marlin/src/feature/power_loss_recovery.cpp

@@ -151,6 +151,12 @@ void PrintJobRecovery::save(const bool force/*=false*/, const bool save_queue/*=
 
     // Machine state
     COPY(info.current_position, current_position);
+    #if HAS_HOME_OFFSET
+      COPY(info.home_offset, home_offset);
+    #endif
+    #if HAS_POSITION_SHIFT
+      COPY(info.position_shift, position_shift);
+    #endif
     info.feedrate = uint16_t(feedrate_mm_s * 60.0f);
 
     #if HOTENDS > 1
@@ -187,7 +193,7 @@ void PrintJobRecovery::save(const bool force/*=false*/, const bool save_queue/*=
       info.retract_hop = fwretract.current_hop;
     #endif
 
-    //relative mode
+    // Relative mode
     info.relative_mode = relative_mode;
     info.relative_modes_e = gcode.axis_relative_modes[E_AXIS];
 
@@ -239,9 +245,9 @@ void PrintJobRecovery::resume() {
     gcode.process_subcommands_now_P(PSTR("M420 S0 Z0"));
   #endif
 
-  // Set Z to 0, raise Z by 2mm, and Home (XY only for Cartesian) with no raise
-  // (Only do simulated homing in Marlin Dev Mode.)
-  gcode.process_subcommands_now_P(PSTR("G92.0 Z0\nG1 Z" STRINGIFY(RECOVERY_ZRAISE) "\nG28 R0"
+  // Set Z to 0, raise Z by RECOVERY_ZRAISE, and Home (XY only for Cartesian)
+  // with no raise. (Only do simulated homing in Marlin Dev Mode.)
+  gcode.process_subcommands_now_P(PSTR("G92.9 E0 Z0\nG1 Z" STRINGIFY(RECOVERY_ZRAISE) "\nG28 R0"
     #if ENABLED(MARLIN_DEV_MODE)
       " S"
     #elif !IS_KINEMATIC
@@ -252,7 +258,7 @@ void PrintJobRecovery::resume() {
   // Pretend that all axes are homed
   axis_homed = axis_known_position = xyz_bits;
 
-  char cmd[40], str_1[16], str_2[16];
+  char cmd[50], str_1[16], str_2[16];
 
   // Select the previously active tool (with no_move)
   #if EXTRUDERS > 1
@@ -315,16 +321,16 @@ void PrintJobRecovery::resume() {
     memcpy(&mixer.gradient, &info.gradient, sizeof(info.gradient));
   #endif
 
-  // Restore Z (plus raise) and E positions with G92.0
-  dtostrf(info.current_position[Z_AXIS] + RECOVERY_ZRAISE, 1, 3, str_1);
-  dtostrf(info.current_position[E_AXIS]
-    #if ENABLED(SAVE_EACH_CMD_MODE)
-      - 5 // Extra extrusion on restart
+  // Extrude and retract to clean the nozzle
+  #if POWER_LOSS_PURGE_LEN
+    //sprintf_P(cmd, PSTR("G1 E%d F200"), POWER_LOSS_PURGE_LEN);
+    //gcode.process_subcommands_now(cmd);
+    gcode.process_subcommands_now_P(PSTR("G1 E" STRINGIFY(POWER_LOSS_PURGE_LEN) " F200"));
   #endif
-    , 1, 3, str_2
-  );
-  sprintf_P(cmd, PSTR("G92.0 Z%s E%s"), str_1, str_2);
+  #if POWER_LOSS_RETRACT_LEN
+    sprintf_P(cmd, PSTR("G1 E%d F3000"), POWER_LOSS_PURGE_LEN - POWER_LOSS_RETRACT_LEN);
     gcode.process_subcommands_now(cmd);
+  #endif
 
   // Move back to the saved XY
   dtostrf(info.current_position[X_AXIS], 1, 3, str_1);
@@ -337,13 +343,37 @@ void PrintJobRecovery::resume() {
   sprintf_P(cmd, PSTR("G1 Z%s F200"), str_1);
   gcode.process_subcommands_now(cmd);
 
+  // Un-retract
+  #if POWER_LOSS_PURGE_LEN
+    //sprintf_P(cmd, PSTR("G1 E%d F3000"), POWER_LOSS_PURGE_LEN);
+    //gcode.process_subcommands_now(cmd);
+    gcode.process_subcommands_now_P(PSTR("G1 E" STRINGIFY(POWER_LOSS_PURGE_LEN) " F3000"));
+  #endif
+
   // Restore the feedrate
   sprintf_P(cmd, PSTR("G1 F%d"), info.feedrate);
   gcode.process_subcommands_now(cmd);
 
-  //relative mode
-  if (info.relative_mode) relative_mode = true;
-  if (info.relative_modes_e) gcode.axis_relative_modes[E_AXIS] = true;
+  // Restore E position with G92.9
+  dtostrf(info.current_position[E_AXIS], 1, 3, str_1);
+  sprintf_P(cmd, PSTR("G92.9 E%s"), str_1);
+  gcode.process_subcommands_now(cmd);
+
+  // Relative mode
+  relative_mode = info.relative_mode;
+  gcode.axis_relative_modes[E_AXIS] = info.relative_modes_e;
+
+  #if HAS_HOME_OFFSET || HAS_POSITION_SHIFT
+    LOOP_XYZ(i) {
+      #if HAS_HOME_OFFSET
+        home_offset[i] = info.home_offset[i];
+      #endif
+      #if HAS_POSITION_SHIFT
+        position_shift[i] = info.position_shift[i];
+      #endif
+      update_workspace_offset((AxisEnum)i);
+    }
+  #endif
 
   // Process commands from the old pending queue
   uint8_t c = info.commands_in_queue, r = info.cmd_queue_index_r;
@@ -372,6 +402,25 @@ void PrintJobRecovery::resume() {
           DEBUG_ECHO(info.current_position[i]);
         }
         DEBUG_EOL();
+
+        #if HAS_HOME_OFFSET
+          DEBUG_ECHOPGM("home_offset: ");
+          LOOP_XYZ(i) {
+            if (i) DEBUG_CHAR(',');
+            DEBUG_ECHO(info.home_offset[i]);
+          }
+          DEBUG_EOL();
+        #endif
+
+        #if HAS_POSITION_SHIFT
+          DEBUG_ECHOPGM("position_shift: ");
+          LOOP_XYZ(i) {
+            if (i) DEBUG_CHAR(',');
+            DEBUG_ECHO(info.position_shift[i]);
+          }
+          DEBUG_EOL();
+        #endif
+
         DEBUG_ECHOLNPAIR("feedrate: ", info.feedrate);
 
         #if HOTENDS > 1

Marlin/src/feature/power_loss_recovery.h

@@ -35,6 +35,8 @@
 #define SAVE_INFO_INTERVAL_MS 0
 //#define SAVE_EACH_CMD_MODE
 //#define DEBUG_POWER_LOSS_RECOVERY
+#define POWER_LOSS_PURGE_LEN 20
+#define POWER_LOSS_RETRACT_LEN 10
 
 typedef struct {
   uint8_t valid_head;
@@ -42,6 +44,13 @@ typedef struct {
   // Machine state
   float current_position[NUM_AXIS];
 
+  #if HAS_HOME_OFFSET
+    float home_offset[XYZ];
+  #endif
+  #if HAS_POSITION_SHIFT
+    float position_shift[XYZ];
+  #endif
+
   uint16_t feedrate;
 
   #if HOTENDS > 1

Marlin/src/gcode/geometry/G92.cpp

@@ -33,9 +33,23 @@
  */
 void GcodeSuite::G92() {
 
+  bool didE = false;
+  #if IS_SCARA || !HAS_POSITION_SHIFT
+    bool didXYZ = false;
+  #else
+    constexpr bool didXYZ = false;
+  #endif
+
+  #if USE_GCODE_SUBCODES
+    const uint8_t subcode_G92 = parser.subcode;
+  #else
+    constexpr uint8_t subcode_G92 = 0;
+  #endif
+
+  switch (subcode_G92) {
+    default: break;
     #if ENABLED(CNC_COORDINATE_SYSTEMS)
-    switch (parser.subcode) {
-      case 1:
+      case 1: {
         // Zero the G92 values and restore current position
         #if !IS_SCARA
           LOOP_XYZ(i) {
@@ -46,24 +60,20 @@ void GcodeSuite::G92() {
             }
           }
         #endif // Not SCARA
-        return;
-    }
+      } return;
     #endif
-
-  #if ENABLED(CNC_COORDINATE_SYSTEMS)
-    #define IS_G92_0 (parser.subcode == 0)
-  #else
-    #define IS_G92_0 true
-  #endif
-
-  bool didE = false;
-  #if IS_SCARA || !HAS_POSITION_SHIFT
-    bool didXYZ = false;
-  #else
-    constexpr bool didXYZ = false;
+    #if ENABLED(POWER_LOSS_RECOVERY)
+      case 9: {
+        LOOP_XYZE(i) {
+          if (parser.seenval(axis_codes[i])) {
+            current_position[i] = parser.value_axis_units((AxisEnum)i);
+            if (i == E_AXIS) didE = true; else didXYZ = true;
+          }
+        }
+      } break;
     #endif
-
-  if (IS_G92_0) LOOP_XYZE(i) {
+    case 0: {
+      LOOP_XYZE(i) {
         if (parser.seenval(axis_codes[i])) {
           const float l = parser.value_axis_units((AxisEnum)i),
                       v = i == E_AXIS ? l : LOGICAL_TO_NATIVE(l, i),
@@ -85,6 +95,8 @@ void GcodeSuite::G92() {
           }
         }
       }
+    } break;
+  }
 
   #if ENABLED(CNC_COORDINATE_SYSTEMS)
     // Apply workspace offset to the active coordinate system

Marlin/src/gcode/sdcard/M23.cpp

@@ -31,9 +31,6 @@
  * M23: Open a file
  */
 void GcodeSuite::M23() {
-  #if ENABLED(POWER_LOSS_RECOVERY)
-    card.removeJobRecoveryFile();
-  #endif
   // Simplify3D includes the size, so zero out all spaces (#7227)
   for (char *fn = parser.string_arg; *fn; ++fn) if (*fn == ' ') *fn = '\0';
   card.openFile(parser.string_arg, true);

Marlin/src/sd/cardreader.cpp

@@ -1030,6 +1030,7 @@ void CardReader::printingHasFinished() {
   // be zeroed and written instead of deleted.
   void CardReader::removeJobRecoveryFile() {
     if (jobRecoverFileExists()) {
+      recovery.init();
       removeFile(job_recovery_file_name);
       #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
         SERIAL_ECHOPGM("Power-loss file delete");