Extend M106/M107 for better laser module support (#16082)

Co-authored-by: Scott Lahteine <thinkyhead@users.noreply.github.com>

Marlin/Configuration_adv.h

@@ -3217,6 +3217,18 @@
   #endif
 #endif
 
+/**
+ * Synchronous Laser Control with M106/M107
+ *
+ * Marlin normally applies M106/M107 fan speeds at a time "soon after" processing
+ * a planner block. This is too inaccurate for a PWM/TTL laser attached to the fan
+ * header (as with some add-on laser kits). Enable this option to set fan/laser
+ * speeds with much more exact timing for improved print fidelity.
+ *
+ * NOTE: This option sacrifices some cooling fan speed options.
+ */
+//#define LASER_SYNCHRONOUS_M106_M107
+
 /**
  * Coolant Control
  *

Marlin/src/gcode/temp/M106_M107.cpp

@@ -28,6 +28,10 @@
 #include "../../module/motion.h"
 #include "../../module/temperature.h"
 
+#if ENABLED(LASER_SYNCHRONOUS_M106_M107)
+  #include "../../module/planner.h"
+#endif
+
 #if PREHEAT_COUNT
   #include "../../lcd/marlinui.h"
 #endif
@@ -82,6 +86,8 @@ void GcodeSuite::M106() {
     // Set speed, with constraint
     thermalManager.set_fan_speed(pfan, speed);
 
+    TERN_(LASER_SYNCHRONOUS_M106_M107, planner.buffer_sync_block(BLOCK_FLAG_SYNC_FANS));
+
     if (TERN0(DUAL_X_CARRIAGE, idex_is_duplicating()))  // pfan == 0 when duplicating
       thermalManager.set_fan_speed(1 - pfan, speed);
   }
@@ -92,12 +98,14 @@ void GcodeSuite::M106() {
  */
 void GcodeSuite::M107() {
   const uint8_t pfan = parser.byteval('P', _ALT_P);
-  if (pfan < _CNT_P) {
-    thermalManager.set_fan_speed(pfan, 0);
+  if (pfan >= _CNT_P) return;
 
-    if (TERN0(DUAL_X_CARRIAGE, idex_is_duplicating()))  // pfan == 0 when duplicating
-      thermalManager.set_fan_speed(1 - pfan, 0);
-  }
+  thermalManager.set_fan_speed(pfan, 0);
+
+  if (TERN0(DUAL_X_CARRIAGE, idex_is_duplicating()))  // pfan == 0 when duplicating
+    thermalManager.set_fan_speed(1 - pfan, 0);
+
+  TERN_(LASER_SYNCHRONOUS_M106_M107, planner.buffer_sync_block(BLOCK_FLAG_SYNC_FANS));
 }
 
 #endif // HAS_FAN

Marlin/src/inc/SanityCheck.h

@@ -1217,6 +1217,17 @@ static_assert(Y_MAX_LENGTH >= Y_BED_SIZE, "Movement bounds (Y_MIN_POS, Y_MAX_POS
   #error "To use BED_LIMIT_SWITCHING you must disable PIDTEMPBED."
 #endif
 
+/**
+ * Synchronous M106/M107 checks
+ */
+#if ENABLED(LASER_SYNCHRONOUS_M106_M107)
+  #if FAN_KICKSTART_TIME
+    #error "FAN_KICKSTART_TIME must be 0 with LASER_SYNCHRONOUS_M106_M107 (because the laser will always come on at FULL power)."
+  #elif FAN_MIN_PWM
+    #error "FAN_MIN_PWM must be 0 with LASER_SYNCHRONOUS_M106_M107 (otherwise the laser will never turn OFF)."
+  #endif
+#endif
+
 /**
  * Chamber Heating Options - PID vs Limit Switching
  */

Marlin/src/lcd/TFTGLCD/marlinui_TFTGLCD.cpp

@@ -760,7 +760,7 @@ void MarlinUI::draw_status_screen() {
     #endif
   #endif // HAS_HEATED_BED
 
-  #if FAN_COUNT > 0
+  #if HAS_FAN
     uint16_t spd = thermalManager.fan_speed[0];
 
     #if ENABLED(ADAPTIVE_FAN_SLOWING)
@@ -783,7 +783,7 @@ void MarlinUI::draw_status_screen() {
     else
       picBits &= ~ICON_FAN;
 
-  #endif // FAN_COUNT > 0
+  #endif // HAS_FAN
 
   //
   // Line 9, 10 - icons

Marlin/src/lcd/dwin/e3v2/dwin.cpp

@@ -2152,7 +2152,7 @@ void HMI_SelectFile() {
 
       card.openAndPrintFile(card.filename);
 
-      #if FAN_COUNT > 0
+      #if HAS_FAN
         // All fans on for Ender 3 v2 ?
         // The slicer should manage this for us.
         //for (uint8_t i = 0; i < FAN_COUNT; i++)

Marlin/src/lcd/marlinui.cpp

@@ -22,6 +22,8 @@
 
 #include "../inc/MarlinConfig.h"
 
+#include "../MarlinCore.h" // for printingIsPaused
+
 #ifdef LED_BACKLIGHT_TIMEOUT
   #include "../feature/leds/leds.h"
 #endif
@@ -39,21 +41,21 @@
 MarlinUI ui;
 
 #if HAS_DISPLAY
-  #include "../module/printcounter.h"
-  #include "../MarlinCore.h"
   #include "../gcode/queue.h"
   #include "fontutils.h"
   #include "../sd/cardreader.h"
 #endif
 
 #if ENABLED(DWIN_CREALITY_LCD)
-  #include "../module/printcounter.h"
-  #include "../MarlinCore.h"
   #include "dwin/e3v2/dwin.h"
 #endif
 
-#if HAS_STATUS_MESSAGE
-  #define START_OF_UTF8_CHAR(C) (((C) & 0xC0u) != 0x80U)
+#if ENABLED(LCD_PROGRESS_BAR) && !IS_TFTGLCD_PANEL
+  #define BASIC_PROGRESS_BAR 1
+#endif
+
+#if ANY(HAS_DISPLAY, HAS_STATUS_MESSAGE, BASIC_PROGRESS_BAR)
+  #include "../module/printcounter.h"
 #endif
 
 #if LCD_HAS_WAIT_FOR_MOVE
@@ -535,7 +537,7 @@ bool MarlinUI::get_blink() {
  * This is very display-dependent, so the lcd implementation draws this.
  */
 
-#if ENABLED(LCD_PROGRESS_BAR) && !IS_TFTGLCD_PANEL
+#if BASIC_PROGRESS_BAR
   millis_t MarlinUI::progress_bar_ms; // = 0
   #if PROGRESS_MSG_EXPIRE > 0
     millis_t MarlinUI::expire_status_ms; // = 0
@@ -546,7 +548,7 @@ void MarlinUI::status_screen() {
 
   TERN_(HAS_LCD_MENU, ENCODER_RATE_MULTIPLY(false));
 
-  #if ENABLED(LCD_PROGRESS_BAR) && !IS_TFTGLCD_PANEL
+  #if BASIC_PROGRESS_BAR
 
     //
     // HD44780 implements the following message blinking and
@@ -586,7 +588,7 @@ void MarlinUI::status_screen() {
 
     #endif // PROGRESS_MSG_EXPIRE
 
-  #endif // LCD_PROGRESS_BAR
+  #endif // BASIC_PROGRESS_BAR
 
   #if HAS_LCD_MENU
     if (use_click()) {
@@ -1353,6 +1355,7 @@ void MarlinUI::update() {
   /**
    * Reset the status message
    */
+
   void MarlinUI::reset_status(const bool no_welcome) {
     #if SERVICE_INTERVAL_1 > 0
       static PGMSTR(service1, "> " SERVICE_NAME_1 "!");
@@ -1438,9 +1441,9 @@ void MarlinUI::update() {
 
   void MarlinUI::finish_status(const bool persist) {
 
-    #if HAS_SPI_LCD
+    #if HAS_WIRED_LCD
 
-      #if !(ENABLED(LCD_PROGRESS_BAR) && (PROGRESS_MSG_EXPIRE) > 0)
+      #if !(BASIC_PROGRESS_BAR && (PROGRESS_MSG_EXPIRE) > 0)
         UNUSED(persist);
       #endif
 
@@ -1448,7 +1451,7 @@ void MarlinUI::update() {
         const millis_t ms = millis();
       #endif
 
-      #if ENABLED(LCD_PROGRESS_BAR)
+      #if BASIC_PROGRESS_BAR
         progress_bar_ms = ms;
         #if PROGRESS_MSG_EXPIRE > 0
           expire_status_ms = persist ? 0 : ms + PROGRESS_MSG_EXPIRE;
@@ -1462,7 +1465,7 @@ void MarlinUI::update() {
       #if ENABLED(STATUS_MESSAGE_SCROLLING)
         status_scroll_offset = 0;
       #endif
-    #else // HAS_SPI_LCD
+    #else // HAS_WIRED_LCD
       UNUSED(persist);
     #endif
 

Marlin/src/lcd/marlinui.h

@@ -56,6 +56,8 @@
   #include "../module/motion.h" // for active_extruder
 #endif
 
+#define START_OF_UTF8_CHAR(C) (((C) & 0xC0u) != 0x80U)
+
 #if HAS_WIRED_LCD
 
   enum LCDViewAction : uint8_t {

Marlin/src/module/planner.cpp

@@ -1015,8 +1015,8 @@ void Planner::reverse_pass() {
     // Perform the reverse pass
     block_t *current = &block_buffer[block_index];
 
-    // Only consider non sync and page blocks
-    if (!TEST(current->flag, BLOCK_BIT_SYNC_POSITION) && !IS_PAGE(current)) {
+    // Only consider non sync-and-page blocks
+    if (!(current->flag & BLOCK_MASK_SYNC) && !IS_PAGE(current)) {
       reverse_pass_kernel(current, next);
       next = current;
     }
@@ -1111,7 +1111,7 @@ void Planner::forward_pass() {
     block = &block_buffer[block_index];
 
     // Skip SYNC and page blocks
-    if (!TEST(block->flag, BLOCK_BIT_SYNC_POSITION) && !IS_PAGE(block)) {
+    if (!(block->flag & BLOCK_MASK_SYNC) && !IS_PAGE(block)) {
       // If there's no previous block or the previous block is not
       // BUSY (thus, modifiable) run the forward_pass_kernel. Otherwise,
       // the previous block became BUSY, so assume the current block's
@@ -1147,7 +1147,7 @@ void Planner::recalculate_trapezoids() {
     block_t *prev = &block_buffer[prev_index];
 
     // If not dealing with a sync block, we are done. The last block is not a SYNC block
-    if (!TEST(prev->flag, BLOCK_BIT_SYNC_POSITION)) break;
+    if (!(prev->flag & BLOCK_MASK_SYNC)) break;
 
     // Examine the previous block. This and all following are SYNC blocks
     head_block_index = prev_index;
@@ -1161,7 +1161,7 @@ void Planner::recalculate_trapezoids() {
     next = &block_buffer[block_index];
 
     // Skip sync and page blocks
-    if (!TEST(next->flag, BLOCK_BIT_SYNC_POSITION) && !IS_PAGE(next)) {
+    if (!(next->flag & BLOCK_MASK_SYNC) && !IS_PAGE(next)) {
       next_entry_speed = SQRT(next->entry_speed_sqr);
 
       if (block) {
@@ -1248,6 +1248,63 @@ void Planner::recalculate() {
   recalculate_trapezoids();
 }
 
+#if HAS_FAN && DISABLED(LASER_SYNCHRONOUS_M106_M107)
+  #define HAS_TAIL_FAN_SPEED 1
+#endif
+
+/**
+ * Apply fan speeds
+ */
+#if HAS_FAN
+
+  void Planner::sync_fan_speeds(uint8_t (&fan_speed)[FAN_COUNT]) {
+
+    #if FAN_MIN_PWM != 0 || FAN_MAX_PWM != 255
+      #define CALC_FAN_SPEED(f) (fan_speed[f] ? map(fan_speed[f], 1, 255, FAN_MIN_PWM, FAN_MAX_PWM) : FAN_OFF_PWM)
+    #else
+      #define CALC_FAN_SPEED(f) (fan_speed[f] ?: FAN_OFF_PWM)
+    #endif
+
+    #if ENABLED(FAN_SOFT_PWM)
+      #define _FAN_SET(F) thermalManager.soft_pwm_amount_fan[F] = CALC_FAN_SPEED(F);
+    #elif ENABLED(FAST_PWM_FAN)
+      #define _FAN_SET(F) set_pwm_duty(FAN##F##_PIN, CALC_FAN_SPEED(F));
+    #else
+      #define _FAN_SET(F) analogWrite(pin_t(FAN##F##_PIN), CALC_FAN_SPEED(F));
+    #endif
+    #define FAN_SET(F) do{ kickstart_fan(fan_speed, ms, F); _FAN_SET(F); }while(0)
+
+    const millis_t ms = millis();
+    TERN_(HAS_FAN0, FAN_SET(0));
+    TERN_(HAS_FAN1, FAN_SET(1));
+    TERN_(HAS_FAN2, FAN_SET(2));
+    TERN_(HAS_FAN3, FAN_SET(3));
+    TERN_(HAS_FAN4, FAN_SET(4));
+    TERN_(HAS_FAN5, FAN_SET(5));
+    TERN_(HAS_FAN6, FAN_SET(6));
+    TERN_(HAS_FAN7, FAN_SET(7));
+  }
+
+  #if FAN_KICKSTART_TIME
+
+    void Planner::kickstart_fan(uint8_t (&fan_speed)[FAN_COUNT], const millis_t &ms, const uint8_t f) {
+      static millis_t fan_kick_end[FAN_COUNT] = { 0 };
+      if (fan_speed[f]) {
+        if (fan_kick_end[f] == 0) {
+          fan_kick_end[f] = ms + FAN_KICKSTART_TIME;
+          fan_speed[f] = 255;
+        }
+        else if (PENDING(ms, fan_kick_end[f]))
+          fan_speed[f] = 255;
+      }
+      else
+        fan_kick_end[f] = 0;
+    }
+
+  #endif
+
+#endif // HAS_FAN
+
 /**
  * Maintain fans, paste extruder pressure,
  */
@@ -1257,7 +1314,7 @@ void Planner::check_axes_activity() {
     xyze_bool_t axis_active = { false };
   #endif
 
-  #if HAS_FAN
+  #if HAS_TAIL_FAN_SPEED
     uint8_t tail_fan_speed[FAN_COUNT];
   #endif
 
@@ -1272,13 +1329,12 @@ void Planner::check_axes_activity() {
 
   if (has_blocks_queued()) {
 
-    #if HAS_FAN || ENABLED(BARICUDA)
+    #if EITHER(HAS_TAIL_FAN_SPEED, BARICUDA)
       block_t *block = &block_buffer[block_buffer_tail];
     #endif
 
-    #if HAS_FAN
-      FANS_LOOP(i)
-        tail_fan_speed[i] = thermalManager.scaledFanSpeed(i, block->fan_speed[i]);
+    #if HAS_TAIL_FAN_SPEED
+      FANS_LOOP(i) tail_fan_speed[i] = thermalManager.scaledFanSpeed(i, block->fan_speed[i]);
     #endif
 
     #if ENABLED(BARICUDA)
@@ -1300,9 +1356,8 @@ void Planner::check_axes_activity() {
 
     TERN_(HAS_CUTTER, cutter.refresh());
 
-    #if HAS_FAN
-      FANS_LOOP(i)
-        tail_fan_speed[i] = thermalManager.scaledFanSpeed(i);
+    #if HAS_TAIL_FAN_SPEED
+      FANS_LOOP(i) tail_fan_speed[i] = thermalManager.scaledFanSpeed(i);
     #endif
 
     #if ENABLED(BARICUDA)
@@ -1321,48 +1376,11 @@ void Planner::check_axes_activity() {
 
   //
   // Update Fan speeds
+  // Only if synchronous M106/M107 is disabled
   //
-  #if HAS_FAN
-
-    #if FAN_KICKSTART_TIME > 0
-      static millis_t fan_kick_end[FAN_COUNT] = { 0 };
-      #define KICKSTART_FAN(f)                         \
-        if (tail_fan_speed[f]) {                       \
-          millis_t ms = millis();                      \
-          if (fan_kick_end[f] == 0) {                  \
-            fan_kick_end[f] = ms + FAN_KICKSTART_TIME; \
-            tail_fan_speed[f] = 255;                   \
-          } else if (PENDING(ms, fan_kick_end[f]))     \
-            tail_fan_speed[f] = 255;                   \
-        } else fan_kick_end[f] = 0
-    #else
-      #define KICKSTART_FAN(f) NOOP
-    #endif
-
-    #if FAN_MIN_PWM != 0 || FAN_MAX_PWM != 255
-      #define CALC_FAN_SPEED(f) (tail_fan_speed[f] ? map(tail_fan_speed[f], 1, 255, FAN_MIN_PWM, FAN_MAX_PWM) : FAN_OFF_PWM)
-    #else
-      #define CALC_FAN_SPEED(f) (tail_fan_speed[f] ?: FAN_OFF_PWM)
-    #endif
-
-    #if ENABLED(FAN_SOFT_PWM)
-      #define _FAN_SET(F) thermalManager.soft_pwm_amount_fan[F] = CALC_FAN_SPEED(F);
-    #elif ENABLED(FAST_PWM_FAN)
-      #define _FAN_SET(F) set_pwm_duty(FAN##F##_PIN, CALC_FAN_SPEED(F));
-    #else
-      #define _FAN_SET(F) analogWrite(pin_t(FAN##F##_PIN), CALC_FAN_SPEED(F));
-    #endif
-    #define FAN_SET(F) do{ KICKSTART_FAN(F); _FAN_SET(F); }while(0)
-
-    TERN_(HAS_FAN0, FAN_SET(0));
-    TERN_(HAS_FAN1, FAN_SET(1));
-    TERN_(HAS_FAN2, FAN_SET(2));
-    TERN_(HAS_FAN3, FAN_SET(3));
-    TERN_(HAS_FAN4, FAN_SET(4));
-    TERN_(HAS_FAN5, FAN_SET(5));
-    TERN_(HAS_FAN6, FAN_SET(6));
-    TERN_(HAS_FAN7, FAN_SET(7));
-  #endif // HAS_FAN
+  #if HAS_TAIL_FAN_SPEED
+    sync_fan_speeds(tail_fan_speed);
+  #endif
 
   TERN_(AUTOTEMP, getHighESpeed());
 
@@ -2675,9 +2693,14 @@ bool Planner::_populate_block(block_t * const block, bool split_move,
 
 /**
  * Planner::buffer_sync_block
- * Add a block to the buffer that just updates the position
+ * Add a block to the buffer that just updates the position,
+ * or in case of LASER_SYNCHRONOUS_M106_M107 the fan PWM
  */
-void Planner::buffer_sync_block() {
+void Planner::buffer_sync_block(TERN_(LASER_SYNCHRONOUS_M106_M107, uint8_t sync_flag)) {
+  #if DISABLED(LASER_SYNCHRONOUS_M106_M107)
+    constexpr uint8_t sync_flag = BLOCK_FLAG_SYNC_POSITION;
+  #endif
+
   // Wait for the next available block
   uint8_t next_buffer_head;
   block_t * const block = get_next_free_block(next_buffer_head);
@@ -2685,10 +2708,14 @@ void Planner::buffer_sync_block() {
   // Clear block
   memset(block, 0, sizeof(block_t));
 
-  block->flag = BLOCK_FLAG_SYNC_POSITION;
+  block->flag = sync_flag;
 
   block->position = position;
 
+  #if BOTH(HAS_FAN, LASER_SYNCHRONOUS_M106_M107)
+    FANS_LOOP(i) block->fan_speed[i] = thermalManager.fan_speed[i];
+  #endif
+
   // If this is the first added movement, reload the delay, otherwise, cancel it.
   if (block_buffer_head == block_buffer_tail) {
     // If it was the first queued block, restart the 1st block delivery delay, to
@@ -2876,7 +2903,7 @@ bool Planner::buffer_line(const float &rx, const float &ry, const float &rz, con
 
     block->flag = BLOCK_FLAG_IS_PAGE;
 
-    #if FAN_COUNT > 0
+    #if HAS_FAN
       FANS_LOOP(i) block->fan_speed[i] = thermalManager.fan_speed[i];
     #endif
 

Marlin/src/module/planner.h

@@ -102,6 +102,11 @@ enum BlockFlagBit : char {
   #if ENABLED(DIRECT_STEPPING)
     , BLOCK_BIT_IS_PAGE
   #endif
+
+  // Sync the fan speeds from the block
+  #if ENABLED(LASER_SYNCHRONOUS_M106_M107)
+    , BLOCK_BIT_SYNC_FANS
+  #endif
 };
 
 enum BlockFlag : char {
@@ -112,8 +117,13 @@ enum BlockFlag : char {
   #if ENABLED(DIRECT_STEPPING)
     , BLOCK_FLAG_IS_PAGE            = _BV(BLOCK_BIT_IS_PAGE)
   #endif
+  #if ENABLED(LASER_SYNCHRONOUS_M106_M107)
+    , BLOCK_FLAG_SYNC_FANS          = _BV(BLOCK_BIT_SYNC_FANS)
+  #endif
 };
 
+#define BLOCK_MASK_SYNC ( BLOCK_FLAG_SYNC_POSITION | TERN0(LASER_SYNCHRONOUS_M106_M107, BLOCK_FLAG_SYNC_FANS) )
+
 #if ENABLED(LASER_POWER_INLINE)
 
   typedef struct {
@@ -499,6 +509,16 @@ class Planner {
     // Manage fans, paste pressure, etc.
     static void check_axes_activity();
 
+    // Apply fan speeds
+    #if HAS_FAN
+      static void sync_fan_speeds(uint8_t (&fan_speed)[FAN_COUNT]);
+      #if FAN_KICKSTART_TIME
+        static void kickstart_fan(uint8_t (&fan_speed)[FAN_COUNT], const millis_t &ms, const uint8_t f);
+      #else
+        FORCE_INLINE static void kickstart_fan(uint8_t (&)[FAN_COUNT], const millis_t &, const uint8_t) {}
+      #endif
+    #endif
+
     #if ENABLED(FILAMENT_WIDTH_SENSOR)
       void apply_filament_width_sensor(const int8_t encoded_ratio);
 
@@ -721,9 +741,12 @@ class Planner {
 
     /**
      * Planner::buffer_sync_block
-     * Add a block to the buffer that just updates the position
+     * Add a block to the buffer that just updates the position or in
+     * case of LASER_SYNCHRONOUS_M106_M107 the fan pwm
      */
-    static void buffer_sync_block();
+    static void buffer_sync_block(
+      TERN_(LASER_SYNCHRONOUS_M106_M107, uint8_t sync_flag=BLOCK_FLAG_SYNC_POSITION)
+    );
 
   #if IS_KINEMATIC
     private:

Marlin/src/module/stepper.cpp

@@ -1988,9 +1988,18 @@ uint32_t Stepper::block_phase_isr() {
     // Anything in the buffer?
     if ((current_block = planner.get_current_block())) {
 
-      // Sync block? Sync the stepper counts and return
-      while (TEST(current_block->flag, BLOCK_BIT_SYNC_POSITION)) {
-        _set_position(current_block->position);
+      // Sync block? Sync the stepper counts or fan speeds and return
+      while (current_block->flag & BLOCK_MASK_SYNC) {
+
+        #if ENABLED(LASER_SYNCHRONOUS_M106_M107)
+          const bool is_sync_fans = TEST(current_block->flag, BLOCK_BIT_SYNC_FANS);
+          if (is_sync_fans) planner.sync_fan_speeds(current_block->fan_speed);
+        #else
+          constexpr bool is_sync_fans = false;
+        #endif
+
+        if (!is_sync_fans) _set_position(current_block->position);
+
         discard_current_block();
 
         // Try to get a new block