Optimize MMU behaviour

src/config/config.h

@@ -104,6 +104,7 @@ static constexpr U_mm pulleyHelperMove = 10.0_mm; ///< Helper move for Load/Unlo
 static constexpr U_mm cutLength = 8.0_mm;
 static constexpr U_mm fsensorToNozzle = 30.0_mm; ///< ~20mm from MK4's filament sensor through extruder gears into nozzle
 static constexpr U_mm fsensorToNozzleAvoidGrind = 5.0_mm;
+static constexpr U_mm fsensorToNozzleAvoidGrindUnload = 20.0_mm;
 /// Check the state of FSensor after this amount of filament got (hopefully) pulled out while unloading.
 static constexpr U_mm fsensorUnloadCheckDistance = 40.0_mm;
 

src/logic/command_base.cpp

@@ -212,7 +212,7 @@ void CommandBase::ErrDisengagingIdler() {
 void CommandBase::GoToErrDisengagingIdler(ErrorCode deferredEC) {
     state = ProgressCode::ERRDisengagingIdler;
     deferredErrorCode = deferredEC;
-    ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::off, ml::blink0);
+    ml::leds.ActiveSlotError();
     mi::idler.Disengage();
 }
 

src/logic/cut_filament.cpp

@@ -86,15 +86,15 @@ bool CutFilament::StepInner() {
                 // move selector aside - prepare the blade into active position
                 state = ProgressCode::PreparingBlade;
                 mg::globals.SetFilamentLoaded(cutSlot, mg::FilamentLoadState::AtPulley);
-                ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
+                ml::leds.ActiveSlotProcessing();
                 MoveSelector(cutSlot + 1);
             }
         }
         break;
     case ProgressCode::PreparingBlade:
         if (ms::selector.Slot() == cutSlot + 1) {
             state = ProgressCode::PushingFilament;
-            mpu::pulley.PlanMove(mg::globals.CutLength() + config::cuttingEdgeRetract, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(mg::globals.CutLength() + config::cuttingEdgeRetract, mg::globals.PulleySlowFeedrate_mm_s());
         }
         break;
     case ProgressCode::PushingFilament:
@@ -123,7 +123,7 @@ bool CutFilament::StepInner() {
             // revert move speed
             mg::globals.SetSelectorFeedrate_mm_s(savedSelectorFeedRate_mm_s);
             ms::selector.InvalidateHoming();
-            mpu::pulley.PlanMove(-config::cuttingEdgeRetract, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(-config::cuttingEdgeRetract, mg::globals.PulleySlowFeedrate_mm_s());
         }
         break;
     case ProgressCode::Homing:
@@ -134,7 +134,7 @@ bool CutFilament::StepInner() {
     case ProgressCode::ReturningSelector:
         if (ms::selector.State() == ms::selector.Ready) {
             FinishedOK();
-            ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::on, ml::off);
+            ml::leds.ActiveSlotDonePrimed();
         }
         break;
     case ProgressCode::OK:

src/logic/eject_filament.cpp

@@ -61,7 +61,7 @@ bool EjectFilament::StepInner() {
         if (mi::idler.Engaged()) {
             state = ProgressCode::EjectingFilament;
             mpu::pulley.InitAxis();
-            mpu::pulley.PlanMove(config::ejectFromCuttingEdge, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(config::ejectFromCuttingEdge, mg::globals.PulleySlowFeedrate_mm_s());
         }
         break;
     case ProgressCode::EjectingFilament:

src/logic/feed_to_bondtech.cpp

@@ -17,7 +17,7 @@ void FeedToBondtech::Reset(uint8_t maxRetries) {
     dbg_logic_P(PSTR("\nFeed to Bondtech\n\n"));
     state = EngagingIdler;
     this->maxRetries = maxRetries;
-    ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::blink0);
+    ml::leds.ActiveSlotProcessing();
     mi::idler.Engage(mg::globals.ActiveSlot());
 }
 
@@ -78,7 +78,7 @@ bool FeedToBondtech::Step() {
             mg::globals.SetFilamentLoaded(mg::globals.ActiveSlot(), mg::FilamentLoadState::InNozzle);
             mi::idler.PartiallyDisengage(mg::globals.ActiveSlot());
             // while disengaging the idler, keep on moving with the pulley to avoid grinding while the printer is trying to grab the filament itself
-            mpu::pulley.PlanMove(config::fsensorToNozzleAvoidGrind, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(config::fsensorToNozzleAvoidGrind, mg::globals.PulleySlowFeedrate_mm_s());
             state = PartiallyDisengagingIdler;
         }
         return false;
@@ -95,7 +95,7 @@ bool FeedToBondtech::Step() {
             dbg_logic_P(PSTR("Feed to Bondtech --> Idler disengaged"));
             dbg_logic_fP(PSTR("Pulley end steps %u"), mpu::pulley.CurrentPosition_mm());
             state = OK;
-            ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::on);
+            ml::leds.ActiveSlotDonePrimed();
         }
         return false;
     case OK:

src/logic/feed_to_finda.cpp

@@ -17,7 +17,7 @@ bool FeedToFinda::Reset(bool feedPhaseLimited, bool haltAtEnd) {
     state = EngagingIdler;
     this->feedPhaseLimited = feedPhaseLimited;
     this->haltAtEnd = haltAtEnd;
-    ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
+    ml::leds.ActiveSlotProcessing();
     if (ms::selector.MoveToSlot(mg::globals.ActiveSlot()) != ms::Selector::OperationResult::Accepted) {
         // We can't get any FINDA readings if the selector is at the wrong spot - move it accordingly if necessary
         // And prevent issuing any commands to the idler in such an error state
@@ -44,14 +44,14 @@ bool FeedToFinda::Step() {
             //                mpu::pulley.PlanMove(config::filamentMinLoadedToMMU, config::pulleySlowFeedrate);
             //            }
 
-            mpu::pulley.PlanMove(config::maximumFeedToFinda, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(config::maximumFeedToFinda, mg::globals.PulleySlowFeedrate_mm_s());
             if (feedPhaseLimited) {
                 state = PushingFilament;
             } else {
                 state = PushingFilamentUnlimited;
                 // in unlimited move we plan 2 moves at once to make the move "seamless"
                 // one move has already been planned above, this is the second one
-                mpu::pulley.PlanMove(config::maximumFeedToFinda, config::pulleySlowFeedrate);
+                mpu::pulley.PlanMove(config::maximumFeedToFinda, mg::globals.PulleySlowFeedrate_mm_s());
             }
             mg::globals.SetFilamentLoaded(mg::globals.ActiveSlot(), mg::FilamentLoadState::InSelector);
             mui::userInput.Clear(); // remove all buffered events if any just before we wait for some input
@@ -68,7 +68,7 @@ bool FeedToFinda::Step() {
             return true; // return immediately to allow for a seamless planning of another move (like feeding to bondtech)
         } else if (mm::motion.QueueEmpty()) { // all moves have been finished and FINDA didn't switch on
             state = Failed;
-            ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::off, ml::blink0);
+            ml::leds.ActiveSlotError();
         }
     }
         return false;
@@ -85,7 +85,7 @@ bool FeedToFinda::Step() {
             return true; // return immediately to allow for a seamless planning of another move (like feeding to bondtech)
         } else if (mm::motion.PlannedMoves(mm::Pulley) < 2) {
             // plan another move to make the illusion of unlimited moves
-            mpu::pulley.PlanMove(config::maximumFeedToFinda, config::pulleySlowFeedrate);
+            mpu::pulley.PlanMove(config::maximumFeedToFinda, mg::globals.PulleySlowFeedrate_mm_s());
         }
     }
         return false;

src/logic/load_filament.cpp

@@ -50,8 +50,6 @@ void logic::LoadFilament::Reset2(bool feedPhaseLimited) {
     if (!feed.Reset(feedPhaseLimited, true)) {
         // selector refused to move
         GoToErrDisengagingIdler(ErrorCode::FINDA_FLICKERS);
-    } else {
-        ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
     }
 }
 

src/logic/retract_from_finda.cpp

@@ -13,7 +13,7 @@ namespace logic {
 void RetractFromFinda::Reset() {
     dbg_logic_P(PSTR("\nRetract from FINDA\n\n"));
     state = EngagingIdler;
-    ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
+    ml::leds.ActiveSlotProcessing();
     mi::idler.Engage(mg::globals.ActiveSlot());
 }
 
@@ -33,10 +33,10 @@ bool RetractFromFinda::Step() {
                 state = OK;
                 mg::globals.SetFilamentLoaded(mg::globals.ActiveSlot(), mg::FilamentLoadState::AtPulley);
                 dbg_logic_fP(PSTR("Pulley end steps %u"), mpu::pulley.CurrentPosition_mm());
-                ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::off);
+                ml::leds.ActiveSlotDoneEmpty();
             } else { // FINDA didn't switch off
                 state = Failed;
-                ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::off, ml::blink0);
+                ml::leds.ActiveSlotError();
             }
         }
         return false;

src/logic/tool_change.cpp

@@ -39,7 +39,7 @@ bool ToolChange::Reset(uint8_t param) {
     if (mg::globals.FilamentLoaded() >= mg::FilamentLoadState::InSelector) {
         dbg_logic_P(PSTR("Filament is loaded --> unload"));
         state = ProgressCode::UnloadingFilament;
-        unl.Reset(mg::globals.ActiveSlot());
+        unl.Reset2(mg::globals.ActiveSlot());
     } else {
         mg::globals.SetFilamentLoaded(plannedSlot, mg::FilamentLoadState::InSelector); // activate the correct slot, feed uses that
         if (feed.Reset(true, false)) {
@@ -54,20 +54,19 @@ bool ToolChange::Reset(uint8_t param) {
     return true;
 }
 
-void logic::ToolChange::GoToFeedingToBondtech() {
-    ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
+void ToolChange::GoToFeedingToBondtech() {
     james.Reset(3);
     state = ProgressCode::FeedingToBondtech;
     error = ErrorCode::RUNNING;
 }
 
-void logic::ToolChange::ToolChangeFinishedCorrectly() {
-    ml::leds.SetPairButOffOthers(mg::globals.ActiveSlot(), ml::on, ml::off);
+void ToolChange::ToolChangeFinishedCorrectly() {
+    ml::leds.ActiveSlotDonePrimed();
     mui::userInput.SetPrinterInCharge(false);
     FinishedOK();
 }
 
-void logic::ToolChange::GoToFeedingToFinda() {
+void ToolChange::GoToFeedingToFinda() {
     state = ProgressCode::FeedingToFinda;
     error = ErrorCode::RUNNING;
     mg::globals.SetFilamentLoaded(plannedSlot, mg::FilamentLoadState::AtPulley);

src/logic/unload_filament.cpp

@@ -28,11 +28,17 @@ bool UnloadFilament::Reset(uint8_t /*param*/) {
     mpu::pulley.InitAxis();
     state = ProgressCode::UnloadingToFinda;
     error = ErrorCode::RUNNING;
+    skipDisengagingIdler = false;
     unl.Reset(maxRetries);
-    ml::leds.SetAllOff();
     return true;
 }
 
+bool UnloadFilament::Reset2(uint8_t param) {
+    bool rv = Reset(param);
+    skipDisengagingIdler = true;
+    return rv;
+}
+
 void UnloadFilament::UnloadFinishedCorrectly() {
     FinishedOK();
     mpu::pulley.Disable();
@@ -77,7 +83,11 @@ bool UnloadFilament::StepInner() {
                 GoToErrDisengagingIdler(ErrorCode::FINDA_DIDNT_SWITCH_OFF); // signal unloading error
             } else {
                 state = ProgressCode::DisengagingIdler;
-                mi::idler.Disengage();
+                if (skipDisengagingIdler && ms::selector.State() == ms::Selector::Ready) {
+                    UnloadFinishedCorrectly(); // skip disengaging the Idler - to be used inside ToolChange to speed up
+                } else {
+                    mi::idler.Disengage();
+                }
             }
         }
         return false;

src/logic/unload_filament.h

@@ -12,12 +12,15 @@ namespace logic {
 class UnloadFilament : public CommandBase {
 public:
     inline constexpr UnloadFilament()
-        : CommandBase() {}
+        : CommandBase()
+        , skipDisengagingIdler(false) {}
 
     /// Restart the automaton
     /// @param param is not used, always unloads from the active slot
     bool Reset(uint8_t param) override;
 
+    bool Reset2(uint8_t param);
+
     /// @returns true if the state machine finished its job, false otherwise
     bool StepInner() override;
 
@@ -32,6 +35,7 @@ class UnloadFilament : public CommandBase {
     UnloadToFinda unl;
     FeedToFinda feed;
     RetractFromFinda retract;
+    bool skipDisengagingIdler;
 };
 
 /// The one and only instance of UnloadFilament state machine in the FW

src/logic/unload_to_finda.cpp

@@ -8,6 +8,7 @@
 #include "../modules/motion.h"
 #include "../modules/permanent_storage.h"
 #include "../modules/pulley.h"
+#include "../modules/timebase.h"
 
 namespace logic {
 
@@ -19,19 +20,40 @@ void UnloadToFinda::Reset(uint8_t maxTries) {
     } else {
         // FINDA is sensing the filament, plan moves to unload it
         state = EngagingIdler;
-        mi::idler.Engage(mg::globals.ActiveSlot());
+        mi::idler.PartiallyDisengage(mg::globals.ActiveSlot()); // basically prepare before the active slot - saves ~1s
+        started_ms = mt::timebase.Millis();
+        ml::leds.ActiveSlotProcessing();
     }
 }
 
 bool UnloadToFinda::Step() {
     switch (state) {
+    // start by engaging the idler into intermediate position
+    // Then, wait for !fsensor.Pressed: that's to speed-up the pull process - unload operation will be started during the purging moves
+    // and as soon as the fsensor turns off, the MMU engages the idler fully and starts pulling.
+    // It will not wait for the extruder to finish the relieve move.
+    // However, such an approach breaks running the MMU on a non-reworked MK4/C1, which hasn't been officially supported, but possible (with some level of uncertainity).
     case EngagingIdler:
-        if (mg::globals.FilamentLoaded() >= mg::FilamentLoadState::InSelector) {
-            state = UnloadingToFinda;
-            mpu::pulley.InitAxis();
-            ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::blink0);
+        if (!mi::idler.PartiallyDisengaged()) { // just waiting for Idler to get into the target intermediate position
+            return false;
+        }
+        if (mfs::fsensor.Pressed()) { // still pressed, printer didn't free the filament yet
+            if (mt::timebase.Elapsed(started_ms, 4000)) {
+                state = FailedFSensor; // fsensor didn't turn off within 4 seconds, something is seriously wrong
+            }
+            return false;
         } else {
-            state = FailedFINDA;
+            // fsensor is OFF and Idler is partially engaged, engage the Idler fully and pull
+            if (mg::globals.FilamentLoaded() >= mg::FilamentLoadState::InSelector) {
+                state = UnloadingToFinda;
+                mpu::pulley.InitAxis();
+                mi::idler.Engage(mg::globals.ActiveSlot());
+
+                //  slow move for the first few millimeters - help the printer relieve the filament while engaging the Idler fully
+                mpu::pulley.PlanMove(-config::fsensorToNozzleAvoidGrindUnload, mg::globals.PulleySlowFeedrate_mm_s(), mg::globals.PulleySlowFeedrate_mm_s());
+            } else {
+                state = FailedFINDA;
+            }
         }
         return false;
     case UnloadingToFinda:
@@ -55,17 +77,20 @@ bool UnloadToFinda::Step() {
             // This scenario should not be tried again - repeating it may cause more damage to filament + potentially more collateral damage
             state = FailedFSensor;
             mm::motion.AbortPlannedMoves(); // stop rotating the pulley
-            ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::off);
+            ml::leds.ActiveSlotDoneEmpty();
         } else if (!mf::finda.Pressed()) {
             // detected end of filament
             state = OK;
             mm::motion.AbortPlannedMoves(); // stop rotating the pulley
-            ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::off);
+            ml::leds.ActiveSlotDoneEmpty();
         } else if (/*tmc2130_read_gstat() &&*/ mm::motion.QueueEmpty()) {
             // we reached the end of move queue, but the FINDA didn't switch off
             // two possible causes - grinded filament or malfunctioning FINDA
             if (--maxTries) {
-                Reset(maxTries); // try again
+                // Ideally, the Idler shall rehome and then try again.
+                // That would auto-resolve errors caused by slipped or misaligned Idler
+                mi::idler.InvalidateHoming();
+                Reset(maxTries);
             } else {
                 state = FailedFINDA;
             }

src/logic/unload_to_finda.h

@@ -24,7 +24,8 @@ struct UnloadToFinda {
     inline constexpr UnloadToFinda()
         : state(OK)
         , maxTries(3)
-        , unloadStart_mm(0) {}
+        , unloadStart_mm(0)
+        , started_ms(0) {}
 
     /// Restart the automaton
     /// @param maxTries maximum number of retried attempts before reporting a fail
@@ -40,6 +41,7 @@ struct UnloadToFinda {
     uint8_t state;
     uint8_t maxTries;
     int32_t unloadStart_mm; // intentionally trying to avoid using U_mm because it is a float (reps. long double)
+    uint16_t started_ms; // timeout on fsensor turn off
 };
 
 } // namespace logic

src/main.cpp

@@ -125,7 +125,7 @@ static void setup2() {
 
         // activate the correct LED if filament is present
         if (mg::globals.FilamentLoaded() > mg::FilamentLoadState::AtPulley) {
-            ml::leds.SetMode(mg::globals.ActiveSlot(), ml::green, ml::on);
+            ml::leds.ActiveSlotDonePrimed();
         }
     }
 

src/modules/idler.cpp

@@ -104,7 +104,7 @@ Idler::OperationResult Idler::PlanMoveInner(uint8_t slot, Operation plannedOp) {
     }
 
     // already engaged or disengaged
-    if (currentlyEngaged == plannedMove) {
+    if (currentlyEngaged == plannedMove && currentSlot == plannedSlot) {
         return OperationResult::Accepted;
     }
 

src/modules/leds.cpp

@@ -2,6 +2,7 @@
 #include "leds.h"
 #include "../hal/shr16.h"
 #include "timebase.h"
+#include "globals.h"
 
 namespace modules {
 namespace leds {
@@ -68,5 +69,21 @@ void LEDs::SetAllOff() {
     }
 }
 
+void LEDs::ActiveSlotProcessing() {
+    SetPairButOffOthers(mg::globals.ActiveSlot(), ml::blink0, ml::off);
+}
+
+void LEDs::ActiveSlotError() {
+    SetPairButOffOthers(mg::globals.ActiveSlot(), ml::off, ml::blink0);
+}
+
+void LEDs::ActiveSlotDoneEmpty() {
+    SetPairButOffOthers(mg::globals.ActiveSlot(), ml::off, ml::off);
+}
+
+void LEDs::ActiveSlotDonePrimed() {
+    SetPairButOffOthers(mg::globals.ActiveSlot(), ml::on, ml::off);
+}
+
 } // namespace leds
 } // namespace modules