Spindle/Laser power in planner blocks (#14437)

Marlin/src/HAL/HAL_AVR/fast_pwm.cpp

@@ -23,7 +23,7 @@
 
 #include "../../inc/MarlinConfigPre.h"
 
-#if ENABLED(FAST_PWM_FAN)
+#if ENABLED(FAST_PWM_FAN) || SPINDLE_LASER_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
+#endif // FAST_PWM_FAN || SPINDLE_LASER_PWM
 #endif // __AVR__

Marlin/src/HAL/HAL_LPC1768/fast_pwm.cpp

@@ -24,7 +24,7 @@
 
 #include "../../inc/MarlinConfigPre.h"
 
-#if ENABLED(FAST_PWM_FAN)
+#if ENABLED(FAST_PWM_FAN) || SPINDLE_LASER_PWM
 
 #include <pwm.h>
 
@@ -36,5 +36,5 @@ void set_pwm_duty(const pin_t pin, const uint16_t v, const uint16_t v_size/*=255
   pwm_write_ratio(pin, invert ? 1.0f - (float)v / v_size : (float)v / v_size);
 }
 
-#endif // FAST_PWM_FAN
+#endif // FAST_PWM_FAN || SPINDLE_LASER_PWM
 #endif // TARGET_LPC1768

Marlin/src/feature/spindle_laser.cpp

@@ -34,14 +34,16 @@ SpindleLaser cutter;
 
 cutter_power_t SpindleLaser::power; // = 0
 
+#define SPINDLE_LASER_PWM_OFF ((SPINDLE_LASER_PWM_INVERT) ? 255 : 0)
+
 void SpindleLaser::init() {
   OUT_WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH); // Init spindle to off
   #if ENABLED(SPINDLE_CHANGE_DIR)
     OUT_WRITE(SPINDLE_DIR_PIN, SPINDLE_INVERT_DIR ? 255 : 0);   // Init rotation to clockwise (M3)
   #endif
-  #if ENABLED(SPINDLE_LASER_PWM) && PIN_EXISTS(SPINDLE_LASER_PWM)
+  #if ENABLED(SPINDLE_LASER_PWM)
     SET_PWM(SPINDLE_LASER_PWM_PIN);
-    analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_INVERT ? 255 : 0);  // set to lowest speed
+    analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF);  // set to lowest speed
   #endif
 }
 
@@ -54,34 +56,34 @@ void SpindleLaser::init() {
    */
   void SpindleLaser::set_ocr(const uint8_t ocr) {
     WRITE(SPINDLE_LASER_ENA_PIN, SPINDLE_LASER_ACTIVE_HIGH); // turn spindle on (active low)
-    #if ENABLED(SPINDLE_LASER_PWM)
+    analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), ocr ^ SPINDLE_LASER_PWM_OFF);
-      analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), (SPINDLE_LASER_PWM_INVERT) ? 255 - ocr : ocr);
-    #endif
   }
 
 #endif
 
-void SpindleLaser::update_output() {
+void SpindleLaser::apply_power(const cutter_power_t inpow) {
-  const bool ena = enabled();
+  static cutter_power_t last_power_applied = 0;
+  if (inpow == last_power_applied) return;
+  last_power_applied = inpow;
   #if ENABLED(SPINDLE_LASER_PWM)
-    if (ena) {
+    if (enabled()) {
+      #define _scaled(F) ((F - (SPEED_POWER_INTERCEPT)) * inv_slope)
       constexpr float inv_slope = RECIPROCAL(SPEED_POWER_SLOPE),
-                      min_ocr = (SPEED_POWER_MIN - (SPEED_POWER_INTERCEPT)) * inv_slope,  // Minimum allowed
+                      min_ocr = _scaled(SPEED_POWER_MIN),
-                      max_ocr = (SPEED_POWER_MAX - (SPEED_POWER_INTERCEPT)) * inv_slope;  // Maximum allowed
+                      max_ocr = _scaled(SPEED_POWER_MAX);
       int16_t ocr_val;
-           if (power <= SPEED_POWER_MIN) ocr_val = min_ocr;                               // Use minimum if set below
+           if (inpow <= SPEED_POWER_MIN) ocr_val = min_ocr;       // Use minimum if set below
-      else if (power >= SPEED_POWER_MAX) ocr_val = max_ocr;                               // Use maximum if set above
+      else if (inpow >= SPEED_POWER_MAX) ocr_val = max_ocr;       // Use maximum if set above
-      else ocr_val = (power - (SPEED_POWER_INTERCEPT)) * inv_slope;                       // Use calculated OCR value
+      else ocr_val = _scaled(inpow);                              // Use calculated OCR value
-      set_ocr(ocr_val & 0xFF);                                                            // ...limited to Atmel PWM max
+      set_ocr(ocr_val & 0xFF);                                    // ...limited to Atmel PWM max
     }
-    else {                                                                                // Convert RPM to PWM duty cycle
+    else {
-      WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH);                           // Turn spindle off (active low)
+      WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_HIGH);   // Turn spindle off (active low)
-      analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_INVERT ? 255 : 0);      // Only write low byte
+      analogWrite(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF);  // Only write low byte
     }
   #else
-    WRITE(SPINDLE_LASER_ENA_PIN, ena ? SPINDLE_LASER_ACTIVE_HIGH : !SPINDLE_LASER_ACTIVE_HIGH);
+    WRITE(SPINDLE_LASER_ENA_PIN, (SPINDLE_LASER_ACTIVE_HIGH) ? enabled() : !enabled());
   #endif
-  power_delay(ena);
 }
 
 #if ENABLED(SPINDLE_CHANGE_DIR)

Marlin/src/feature/spindle_laser.h

@@ -36,10 +36,10 @@
 #define MSG_CUTTER(M) _MSG_CUTTER(M)
 
 #if SPEED_POWER_MAX > 255
-  #define cutter_power_t   uint16_t
+  typedef uint16_t cutter_power_t;
   #define CUTTER_MENU_TYPE uint16_5
 #else
-  #define cutter_power_t   uint8_t
+  typedef uint8_t cutter_power_t;
   #define CUTTER_MENU_TYPE uint8
 #endif
 
@@ -51,9 +51,17 @@ public:
 
   static inline bool enabled() { return !!power; }
 
-  static inline void set_power(const uint8_t pwr) { power = pwr; update_output(); }
+  static inline void set_power(const cutter_power_t pwr) { power = pwr; }
 
-  static inline void set_enabled(const bool enable) { set_power(enable ? 255 : 0); }
+  static inline void refresh() { apply_power(power); }
+
+  static inline void set_enabled(const bool enable) {
+    const bool was = enabled();
+    set_power(enable ? 255 : 0);
+    if (was != enable) power_delay();
+  }
+
+  static void apply_power(const cutter_power_t inpow);
 
   //static bool active() { return READ(SPINDLE_LASER_ENA_PIN) == SPINDLE_LASER_ACTIVE_HIGH; }
 
@@ -61,11 +69,15 @@ public:
 
   #if ENABLED(SPINDLE_LASER_PWM)
     static void set_ocr(const uint8_t ocr);
-    static inline void set_ocr_power(const uint8_t pwr) { power = pwr; set_ocr(pwr); }
+    static inline void set_ocr_power(const cutter_power_t pwr) { power = pwr; set_ocr(pwr); }
   #endif
 
   // Wait for spindle to spin up or spin down
-  static inline void power_delay(const bool on) { safe_delay(on ? SPINDLE_LASER_POWERUP_DELAY : SPINDLE_LASER_POWERDOWN_DELAY); }
+  static inline void power_delay() {
+    #if SPINDLE_LASER_POWERUP_DELAY || SPINDLE_LASER_POWERDOWN_DELAY
+      safe_delay(enabled() ? SPINDLE_LASER_POWERUP_DELAY : SPINDLE_LASER_POWERDOWN_DELAY);
+    #endif
+  }
 
   #if ENABLED(SPINDLE_CHANGE_DIR)
     static void set_direction(const bool reverse);

Marlin/src/gcode/control/M3-M5.cpp

@@ -29,10 +29,20 @@
 #include "../../module/stepper.h"
 
 /**
- *  M3 - Cutter ON (Clockwise)
+ * Laser:
- *  M4 - Cutter ON (Counter-clockwise)
  *
- *    S<power> - Set power. S0 turns it off.
+ *  M3 - Laser ON/Power (Ramped power)
+ *  M4 - Laser ON/Power (Continuous power)
+ *
+ *    S<power> - Set power. S0 will turn the laser off.
+ *    O<ocr>   - Set power and OCR
+ *
+ * Spindle:
+ *
+ *  M3 - Spindle ON (Clockwise)
+ *  M4 - Spindle ON (Counter-clockwise)
+ *
+ *    S<power> - Set power. S0 will turn the spindle off.
  *    O<ocr>   - Set power and OCR
  *
  *  If no PWM pin is defined then M3/M4 just turns it on.
@@ -61,12 +71,14 @@
  */
 void GcodeSuite::M3_M4(const bool is_M4) {
 
-  planner.synchronize();   // Wait for previous movement commands (G0/G0/G2/G3) to complete before changing power
+  #if ENABLED(SPINDLE_FEATURE)
+    planner.synchronize();   // Wait for movement to complete before changing power
+  #endif
 
   cutter.set_direction(is_M4);
 
   #if ENABLED(SPINDLE_LASER_PWM)
-    if (parser.seen('O'))
+    if (parser.seenval('O'))
       cutter.set_ocr_power(parser.value_byte()); // The OCR is a value from 0 to 255 (uint8_t)
     else
       cutter.set_power(parser.intval('S', 255));
@@ -79,7 +91,9 @@ void GcodeSuite::M3_M4(const bool is_M4) {
  * M5 - Cutter OFF
  */
 void GcodeSuite::M5() {
-  planner.synchronize();
+  #if ENABLED(SPINDLE_FEATURE)
+    planner.synchronize();
+  #endif
   cutter.set_enabled(false);
 }
 

Marlin/src/lcd/menu/menu_spindle_laser.cpp

@@ -38,7 +38,7 @@
     BACK_ITEM(MSG_MAIN);
     if (cutter.enabled()) {
       #if ENABLED(SPINDLE_LASER_PWM)
-        EDIT_ITEM(CUTTER_MENU_TYPE, MSG_CUTTER(POWER), &cutter.power, SPEED_POWER_MIN, SPEED_POWER_MAX, cutter.update_output);
+        EDIT_ITEM(CUTTER_MENU_TYPE, MSG_CUTTER(POWER), &cutter.power, SPEED_POWER_MIN, SPEED_POWER_MAX);
       #endif
       ACTION_ITEM(MSG_CUTTER(OFF), cutter.disable);
     }

Marlin/src/module/planner.cpp

@@ -100,6 +100,10 @@
   #include "../feature/power_loss_recovery.h"
 #endif
 
+#if HAS_CUTTER
+  #include "../feature/spindle_laser.h"
+#endif
+
 // Delay for delivery of first block to the stepper ISR, if the queue contains 2 or
 // fewer movements. The delay is measured in milliseconds, and must be less than 250ms
 #define BLOCK_DELAY_FOR_1ST_MOVE 100
@@ -1220,6 +1224,11 @@ void Planner::check_axes_activity() {
     #endif
   }
   else {
+
+    #if HAS_CUTTER
+      cutter.refresh();
+    #endif
+
     #if FAN_COUNT > 0
       FANS_LOOP(i)
         tail_fan_speed[i] = thermalManager.scaledFanSpeed(i);
@@ -1235,6 +1244,9 @@ void Planner::check_axes_activity() {
     #endif
   }
 
+  //
+  // Disable inactive axes
+  //
   #if ENABLED(DISABLE_X)
     if (!axis_active.x) disable_X();
   #endif
@@ -1248,6 +1260,9 @@ void Planner::check_axes_activity() {
     if (!axis_active.e) disable_e_steppers();
   #endif
 
+  //
+  // Update Fan speeds
+  //
   #if FAN_COUNT > 0
 
     #if FAN_KICKSTART_TIME > 0
@@ -1841,6 +1856,10 @@ bool Planner::_populate_block(block_t * const block, bool split_move,
     MIXER_POPULATE_BLOCK();
   #endif
 
+  #if HAS_CUTTER
+    block->cutter_power = cutter.power;
+  #endif
+
   #if FAN_COUNT > 0
     FANS_LOOP(i) block->fan_speed[i] = thermalManager.fan_speed[i];
   #endif
@@ -2354,13 +2373,21 @@ bool Planner::_populate_block(block_t * const block, bool split_move,
 
   #endif
 
+  #ifdef USE_CACHED_SQRT
+    #define CACHED_SQRT(N, V) \
+      static float saved_V, N; \
+      if (V != saved_V) { N = SQRT(V); saved_V = V; }
+  #else
+    #define CACHED_SQRT(N, V) const float N = SQRT(V)
+  #endif
+
   #if HAS_CLASSIC_JERK
 
     /**
      * Adapted from Průša MKS firmware
      * https://github.com/prusa3d/Prusa-Firmware
      */
-    const float nominal_speed = SQRT(block->nominal_speed_sqr);
+    CACHED_SQRT(nominal_speed, block->nominal_speed_sqr);
 
     // Exit speed limited by a jerk to full halt of a previous last segment
     static float previous_safe_speed;
@@ -2401,7 +2428,8 @@ bool Planner::_populate_block(block_t * const block, bool split_move,
 
       // The junction velocity will be shared between successive segments. Limit the junction velocity to their minimum.
       // Pick the smaller of the nominal speeds. Higher speed shall not be achieved at the junction during coasting.
-      const float previous_nominal_speed = SQRT(previous_nominal_speed_sqr);
+      CACHED_SQRT(previous_nominal_speed, previous_nominal_speed_sqr);
+
       vmax_junction = _MIN(nominal_speed, previous_nominal_speed);
 
       // Now limit the jerk in all axes.

Marlin/src/module/planner.h

@@ -51,6 +51,10 @@
   #include "../feature/mixing.h"
 #endif
 
+#if HAS_CUTTER
+  #include "../feature/spindle_laser.h"
+#endif
+
 // Feedrate for manual moves
 #ifdef MANUAL_FEEDRATE
   constexpr xyze_feedrate_t manual_feedrate_mm_m = MANUAL_FEEDRATE;
@@ -145,6 +149,10 @@ typedef struct block_t {
            final_rate,                      // The minimal rate at exit
            acceleration_steps_per_s2;       // acceleration steps/sec^2
 
+  #if HAS_CUTTER
+    cutter_power_t cutter_power;            // Power level for Spindle, Laser, etc.
+  #endif
+
   #if FAN_COUNT > 0
     uint8_t fan_speed[FAN_COUNT];
   #endif

Marlin/src/module/stepper.cpp

@@ -1667,6 +1667,10 @@ uint32_t Stepper::stepper_block_phase_isr() {
           return interval; // No more queued movements!
       }
 
+      #if HAS_CUTTER
+        cutter.apply_power(current_block->cutter_power);
+      #endif
+
       #if ENABLED(POWER_LOSS_RECOVERY)
         recovery.info.sdpos = current_block->sdpos;
       #endif