Schematic diagram for THC

.gitignore

@@ -10,3 +10,12 @@ embedded/dist
 .vscode/
 .history/
 *.pyc
+.vs/
+Debug/
+Release/
+*.vsarduino.h
+__vm/
+*.user
+*.vcxproj
+*.vcxproj.filters
+*.suo

Grbl_Esp32.sln

@@ -0,0 +1,31 @@
+
+Microsoft Visual Studio Solution File, Format Version 12.00
+# Visual Studio Version 16
+VisualStudioVersion = 16.0.29306.81
+MinimumVisualStudioVersion = 10.0.40219.1
+Project("{8BC9CEB8-8B4A-11D0-8D11-00A0C91BC942}") = "Grbl_Esp32", "Grbl_Esp32.vcxproj", "{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}"
+EndProject
+Global
+	GlobalSection(SolutionConfigurationPlatforms) = preSolution
+		Debug|x64 = Debug|x64
+		Debug|x86 = Debug|x86
+		Release|x64 = Release|x64
+		Release|x86 = Release|x86
+	EndGlobalSection
+	GlobalSection(ProjectConfigurationPlatforms) = postSolution
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Debug|x64.ActiveCfg = Debug|x64
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Debug|x64.Build.0 = Debug|x64
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Debug|x86.ActiveCfg = Debug|Win32
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Debug|x86.Build.0 = Debug|Win32
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Release|x64.ActiveCfg = Release|x64
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Release|x64.Build.0 = Release|x64
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Release|x86.ActiveCfg = Release|Win32
+		{11C8A44F-A303-4885-B5AD-5B65F7FE41C0}.Release|x86.Build.0 = Release|Win32
+	EndGlobalSection
+	GlobalSection(SolutionProperties) = preSolution
+		HideSolutionNode = FALSE
+	EndGlobalSection
+	GlobalSection(ExtensibilityGlobals) = postSolution
+		SolutionGuid = {EEC94F4B-059C-4596-94B8-1C4C9CE5E0DD}
+	EndGlobalSection
+EndGlobal

Grbl_Esp32/Custom/torchHeightControl.cpp

@@ -0,0 +1,176 @@
+/*
+	torchHeightControl.cpp
+	Part of Grbl_ESP32
+
+	copyright (c) 2018 -	Bart Dring This file was modified for use on the ESP32
+	CPU. Do not use this with Grbl for atMega328P
+
+	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 <http://www.gnu.org/licenses/>.
+
+	--------------------------------------------------------------
+
+ 	This contains all the special features required for "Plasma Torch Height Control"
+	This Torch Height Control Custom File Was Created By: William Curry
+*/
+// This file is enabled by defining: CUSTOM_CODE_FILENAME "Custom/torchHeightControl.cpp"
+// in Machines/6_pack_thc.h, thus causing this file to be included
+// from ../custom_code.cpp
+static TaskHandle_t THCSyncTaskHandle = 0;
+static TaskHandle_t THCVoltageTaskHandle = 0;
+unsigned long THCCounter = 0; //For debugging only
+unsigned long lastDebugPrintTimeMillis; //For debugging only, last time debug info was printed
+bool alwaysPrintWhenTHCRunning = true;
+unsigned long arcOnTime; //milliseconds at which plasma arc was turned on
+//Be careful with this next setting becuase if you send to many steps to stepper.cpp per iteration it may overrun how many steps the machine can do per milliseond at slower x/y speeds
+int numberStepsPerIteration = 1;//How many steps we want to send to the stepper.cpp for each iteration of THC this will be an adjustable setting in the future %%%%%%%%%%
+bool thcRunning;
+int thcIterationMs = 20;
+int directionDownPinState = 1;
+int directionUpPinState = 0;
+float thcPinVoltage;
+float torchVoltage;
+float torchVoltageFiltered; ///Current filtered value used for THC routine
+float  voltageSetpoint;
+int voltageInt;
+int currentDirectionState; ////get state of direction pin
+bool directionDifference;
+int thcZStep;
+int thcDirDown;
+// Function // Step Z Down Voltage too high
+void thcStepZDown(){
+		if ((thc_debug_setting->get()||alwaysPrintWhenTHCRunning) && ((millis() - lastDebugPrintTimeMillis) > thc_debugprint_millis->get()) )
+		{
+            grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Setpoint = %4.1f THC Voltage = %4.1f Moving Z Down", voltageSetpoint, torchVoltageFiltered);
+		    lastDebugPrintTimeMillis = millis();
+		}
+		thcZStep = numberStepsPerIteration; // set the number of steps per iteration of THC so stepper.cpp can execute the steps
+		thcDirDown = 1; //Set the step direction so stepper.cpp knows which way to step
+}
+
+// Function // Step Z Up Voltage too Low
+void thcStepZUp(){
+		if ((thc_debug_setting->get()||alwaysPrintWhenTHCRunning) && ((millis() - lastDebugPrintTimeMillis) > thc_debugprint_millis->get()) )
+		{
+            grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Setpoint = %4.1f THC Voltage = %4.1f Moving Z Up", voltageSetpoint, torchVoltageFiltered);
+		    lastDebugPrintTimeMillis = millis();
+		}
+		thcZStep = numberStepsPerIteration; // set the number of steps per iteration of THC so stepper.cpp can execute the steps
+		thcDirDown = 0; //Set the step direction so stepper.cpp knows which way to step
+}
+
+void machine_init() {
+    grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "Bill's THC Initialized");
+    // setup a task that will do torch height control
+    xTaskCreatePinnedToCore(THCSyncTask,   // task
+                            "THCSyncTask", // name for task
+                            4096,				// size of task stack
+                            NULL,				// parameters
+                            1,					// priority
+                            &THCSyncTaskHandle,
+                            0 // core
+                           );
+	// setup a task that will filter the torch voltage
+    xTaskCreatePinnedToCore(THCVoltageTask,   // task
+                            "THCVoltageTask", // name for task
+                            4096,				// size of task stack
+                            NULL,				// parameters
+                            1,					// priority
+                            &THCVoltageTaskHandle,
+                            0 // core
+                           );
+}
+
+// this task is the main THC loop
+void THCSyncTask(void* pvParameters) {
+    TickType_t xthcWakeTime;
+    const TickType_t xTHCFrequency = (thc_iter_freq -> get()) + 1; // (ms)
+    xthcWakeTime = xTaskGetTickCount(); // Initialise the xthcWakeTime variable with the current time.
+    while (true) { // don't ever return from this or the task dies
+        //Get the state of the plasma cutter torch on relay
+        uint8_t plasmaState = coolant_get_state(); //Using the coolant flood output to turn on the plasma cutter
+		if(sys.suspend)
+		{
+			coolant_set_state(COOLANT_DISABLE); //Disable plasma if system state is suspended
+		}
+        if(plasmaState && (voltageSetpoint > 30) && !sys.suspend) //Plasma Has Been Turned On and the Voltage Setpoint is greater than 30 volts Start The THC Routine
+        {
+            if((millis()- arcOnTime) > (thc_arc_delay_time->get()))
+            {
+				thcRunning = true;     
+                //digitalWrite(I2SO(24),HIGH);
+                //digitalWrite(I2SO(25),HIGH);
+                //digitalWrite(I2SO(26),HIGH);
+                //digitalWrite(I2SO(27),HIGH);      
+            }
+            else
+            {
+				thcRunning = false; 
+            }
+        }
+        else
+        {
+            arcOnTime = millis(); //Reset arc on delay timer
+			thcRunning = false;
+			thcZStep = 0; //Reset all the steps we sent to stepper.cpp
+            if (thc_debug_setting->get() && ((millis() - lastDebugPrintTimeMillis) > thc_debugprint_millis->get()) )
+            {
+                //grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Interation # %d", THCCounter);
+                grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Voltage Filt = %4.1f", torchVoltageFiltered);
+                grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Voltage Unfiltered = %4.1f", torchVoltage);
+                grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Pin Voltage = %3.2f", thcPinVoltage);
+                grbl_msg_sendf(CLIENT_ALL, MSG_LEVEL_INFO, "THC Voltage Setting = %4.1f", voltageSetpoint);
+                lastDebugPrintTimeMillis = millis();
+            }
+                //digitalWrite(I2SO(24),LOW);
+                //digitalWrite(I2SO(25),LOW);
+                //digitalWrite(I2SO(26),LOW);
+                //digitalWrite(I2SO(27),LOW); 
+        }
+
+		if((torchVoltageFiltered > voltageSetpoint) && thcRunning) //Voltage is too high and were running THC step Z down
+        {
+            thcStepZDown();
+        }
+        else if((torchVoltageFiltered < voltageSetpoint)&& thcRunning) //Voltage is too low and were running THC  step Z up
+        {
+            thcStepZUp();
+        }
+
+        THCCounter ++;
+		voltageSetpoint = (thc_voltage_setting -> get());
+
+        vTaskDelayUntil(&xthcWakeTime, thc_iter_freq -> get() + 1); //Adding +1 so the loop doesn't crash if set to 0
+    }
+}
+
+// this task is THC Voltage Filtering Loop
+void THCVoltageTask(void* pvParameters) {
+    TickType_t xLastVoltageWakeTime;
+    const TickType_t xTHCVoltageFrequency = 2; // (ms)
+    xLastVoltageWakeTime = xTaskGetTickCount(); // Initialise the xLastVoltageWakeTime variable with the current time.
+    while (true) {// don't ever return from this or the task dies
+		voltageInt = analogRead(THC_VOLTAGE_PIN);
+		thcPinVoltage = voltageInt * (3.3 / 4095); //0-3.3 volts at torch input pin
+		torchVoltage =  (thcPinVoltage*(VOLTAGE_DIVIDER_R1+VOLTAGE_DIVIDER_R2))/VOLTAGE_DIVIDER_R2;//0-207 volts for R1 = 470K R2 = 7.6K
+        if(thcRunning) ///If the Main THC Loop is running Start filtering the voltage
+        {
+           torchVoltageFiltered = torchVoltageFiltered * (thc_voltage_filter_value -> get()) + torchVoltage * (1-(thc_voltage_filter_value -> get())); //Rough filter for voltage input
+        }
+        else
+        {
+            torchVoltageFiltered = torchVoltage;
+        }
+        vTaskDelayUntil(&xLastVoltageWakeTime, xTHCVoltageFrequency + 1);
+    }
+}

Grbl_Esp32/Machines/6_pack_stepstick_v1.h

@@ -83,8 +83,8 @@
 #define Y_LIMIT_PIN             GPIO_NUM_32
 #define Z_LIMIT_PIN             GPIO_NUM_35
 #define A_LIMIT_PIN             GPIO_NUM_34
-#define B_LIMIT_PIN             GPIO_NUM_39
-#define C_LIMIT_PIN             GPIO_NUM_36
+//#define B_LIMIT_PIN             GPIO_NUM_39
+//#define C_LIMIT_PIN             GPIO_NUM_36
 
 #define PROBE_PIN               GPIO_NUM_25
 
@@ -117,13 +117,13 @@
 #define COOLANT_FLOOD_PIN       I2SO(27)
 */
 
-/*
+
 // RS485 In socket #3
 #define SPINDLE_TYPE            SPINDLE_TYPE_HUANYANG // only one spindle at a time
 #define HUANYANG_TXD_PIN        GPIO_NUM_26
 #define HUANYANG_RTS_PIN        GPIO_NUM_4
 #define HUANYANG_RXD_PIN        GPIO_NUM_16
-*/
+
 
 
 // === Default settings

Grbl_Esp32/Machines/6_pack_thc.h

@@ -0,0 +1,132 @@
+/*
+    6_pack_thc.h
+
+    Covers all V1 versions V1p0, V1p1, etc
+
+    Part of Grbl_ESP32
+    Pin assignments for the ESP32 I2S 6-axis board
+    2018    - Bart Dring
+    2020    - Mitch Bradley
+    2020    - Michiyasu Odaki
+	2020    - William Curry - Plasma Torch Height Control
+    Grbl_ESP32 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_ESP32.  If not, see <http://www.gnu.org/licenses/>.
+	This 6-Pack Torch Height Control Custom File Was Created By: William Curry
+*/
+#define MACHINE_NAME "6 Pack Controller with Plasma Torch Height Control"
+#define CUSTOM_CODE_FILENAME "Custom/torchHeightControl.cpp"//define the torch height control custom code file
+// tells grbl we have some special functions to call
+#define USE_MACHINE_INIT
+#ifdef N_AXIS
+        #undef N_AXIS
+#endif
+#define N_AXIS 3
+//Enable the SD Card
+#ifndef ENABLE_SD_CARD
+    #define ENABLE_SD_CARD
+#endif
+/// THC Settings, these can be displayed in G Code Sender by Typing $S to show strings or $+ to show numbers like shown below
+#define SHOW_EXTENDED_SETTINGS
+#define DEFAULT_THC_DEBUG 0 //$300=1// Boolean //If true this will print torch height debug information out
+#define DEFAULT_THC_DEBUG_PRINT_MILLIS 5000 //$301=1000//milliseconds // debug print time in milliseconds
+#define DEFAULT_THC_TARGET_VOLTAGE 0 //$302=0// Volts // default target voltage (a real value would be 100 volts) this must be greater than 30 volts for THC to run
+#define DEFAULT_THC_ARC_DELAY_TIME 750 //$303=750//milliseconds // Time for Arc to Start before running THC
+#define DEFAULT_THC_VOLTAGE_FILTER_VALUE 0.98 //$304=0.98//ND// Torch Voltage Filter Time Constant
+#define DEFAULT_THC_ITER_FREQ 5 //$305=5//milliseconds// Torch Height Control Time Between Calls, this will directly effect ...
+// ... the rate at which the Z axis moves. A higher muber means the Z axis will move slower since THC is called less often
+
+// === Special Features
+///Define Torch Height Control
+#define torchHeightControl //Used in stepper.cpp
+/// I2S (steppers & other output-only pins)
+#define USE_I2S_OUT
+// Define USE_I2S_OUT_STREAM if buffering is used.
+// (there will be a delay between the specified I/O operation and the actual I/O execution)
+#define USE_I2S_OUT_STREAM
+#undef USE_RMT_STEPS
+#define STEP_PULSE_DELAY 10 //Mircoseconds to delay between setting direction pin and setting step pin high
+//#define USE_STEPSTICK   //Bill comment makes sure MS1,2,3 !reset and !sleep are set
+/* #ifdef ENABLE_WIFI
+ #undef ENABLE_WIFI ///Turn off wifi since this blocks the ADC Channel 2 Pins from Reading in Voltage Which is needed for THC
+#endif */
+
+#define I2S_OUT_BCK      GPIO_NUM_22
+#define I2S_OUT_WS       GPIO_NUM_17
+#define I2S_OUT_DATA     GPIO_NUM_21
+
+/// Axis Data 
+#define USE_GANGED_AXES // allow two motors on an axis
+
+#define STEPPER_Z_MS3           I2SO(3)   // Z_CS
+#define STEPPER_Y_MS3           I2SO(6)   // Y_CS
+#define STEPPER_X_MS3           I2SO(11)  // X_CS
+#define STEPPER_Y2_MS3           I2SO(14)  // Y2/A_CS
+//#define STEPPER_B_MS3           I2SO(19)  // B_CS
+//#define STEPPER_C_MS3           I2SO(22)  // C_CS
+#define STEPPER_RESET           GPIO_NUM_19
+//Terminal 1
+#define Z_DISABLE_PIN           I2SO(0)
+#define Z_DIRECTION_PIN         I2SO(1)
+#define Z_STEP_PIN              I2SO(2)
+
+//Y Is a Ganged Motor
+#define Y_AXIS_SQUARING
+//Terminal 2
+#define Y_DIRECTION_PIN         I2SO(4)
+#define Y_STEP_PIN              I2SO(5)
+#define Y_DISABLE_PIN           I2SO(7)
+//Terminal 4
+#define Y2_DIRECTION_PIN         I2SO(12) //Motor A Dir
+#define Y2_STEP_PIN              I2SO(13) //Motor A Step
+#define Y2_DISABLE_PIN           I2SO(15) //Motor A Disable
+
+///Terminal 3
+#define X_DISABLE_PIN           I2SO(8)
+#define X_DIRECTION_PIN         I2SO(9)
+#define X_STEP_PIN              I2SO(10)
+/* Bill Comment out these axis'
+
+#define B_DISABLE_PIN           I2SO(16)
+#define B_DIRECTION_PIN         I2SO(17)
+#define B_STEP_PIN              I2SO(18)
+
+#define C_DIRECTION_PIN         I2SO(20)
+#define C_STEP_PIN              I2SO(21)
+#define C_DISABLE_PIN           I2SO(23)
+*/
+/// CNC Modules
+///CNC Module #1 THC Voltage 
+#define THC_VOLTAGE_PIN         GPIO_NUM_32
+
+///Resistance Values needed to determine arc voltage i.e. Vout = (Vs*R2)/(R1+R2)
+#define VOLTAGE_DIVIDER_R1      470 ///470K Ohms
+#define VOLTAGE_DIVIDER_R2      7.6 ///7.6K Ohms
+
+//CNC Module # 2 Opto Isolated
+#define X_LIMIT_PIN             GPIO_NUM_2
+#define Y_LIMIT_PIN             GPIO_NUM_25
+#define Z_LIMIT_PIN             GPIO_NUM_39
+#define PROBE_PIN               GPIO_NUM_36
+
+///CNC Module # 3 Spindle Relay
+#define SPINDLE_TYPE            SPINDLE_TYPE_RELAY
+#define SPINDLE_OUTPUT_PIN       GPIO_NUM_26
+//#define COOLANT_MIST_PIN       GPIO_NUM_26
+///CNC Module # 4 Plasma Torch Relay  AKA Coolant Flood Pin 
+#define COOLANT_FLOOD_PIN       GPIO_NUM_14
+
+///CNC Module # 5 Empty
+
+///Torch Height Control Custom Functions
+void THCSyncTask(void* pvParameters); //Task called for Torch height controlled thats defined in torchHeightControl.cpp
+void THCVoltageTask(void* pvParameters); //Task called for Torch height controlled thats defined in torchHeightControl.cpp
+// === Default settings
+#define DEFAULT_STEP_PULSE_MICROSECONDS I2S_OUT_USEC_PER_PULSE