Workaround planning moves longer than 32K steps

src/config/config.h

@@ -9,10 +9,10 @@
 /// Enable DEBUG_LOGIC to compile debugging and error messages (beware of code base size ;) ) for the logic layer
 //#define DEBUG_LOGIC
 
-/// Enable DEBUG_LOGIC to compile debugging and error messages (beware of code base size ;) ) for the logic layer
+/// Enable DEBUG_MODULES to compile debugging and error messages (beware of code base size ;) ) for the modules layer
 //#define DEBUG_MODULES
 
-/// Enable DEBUG_HAL to compile debugging and error messages (beware of code base size ;) ) for the logic layer
+/// Enable DEBUG_HAL to compile debugging and error messages (beware of code base size ;) ) for the HAL layer
 //#define DEBUG_HAL
 
 /// Wrangler for assorted compile-time configuration and constants.
@@ -53,7 +53,8 @@ static constexpr uint16_t maxStepFrequency = 40000;
 static constexpr uint16_t minStepRate = 120;
 
 /// Size for the motion planner block buffer size
-static constexpr uint8_t blockBufferSize = 2;
+/// Beware of too low setting (esp. because of Motion::PlanLongMove)
+static constexpr uint8_t blockBufferSize = 4;
 
 /// Step timer frequency divider (F = F_CPU / divider)
 static constexpr uint8_t stepTimerFrequencyDivider = 8;
@@ -83,7 +84,7 @@ static constexpr U_mm couplerToBowden = 3.5_mm; /// 3.5_mm /// FINDA Coupler scr
 // just another piece of PLA (probably having more resistance in the tubes)
 // and we are at least 40mm off! It looks like this really depends on the exact position
 // We'll probably need to check for stallguard while pushing the filament to avoid ginding the filament
-static constexpr U_mm defaultBowdenLength = 467.0_mm; /// ~427.0_mm /// Default Bowden length. @TODO Should be stored in EEPROM.
+static constexpr U_mm defaultBowdenLength = 427.0_mm; /// ~427.0_mm /// Default Bowden length. @TODO Should be stored in EEPROM. 392 a 784
 static constexpr U_mm minimumBowdenLength = 341.0_mm; /// ~341.0_mm /// Minimum bowden length. @TODO Should be stored in EEPROM.
 static constexpr U_mm maximumBowdenLength = 792.0_mm; /// ~792.0_mm /// Maximum bowden length. @TODO Should be stored in EEPROM.
 static constexpr U_mm feedToFinda = cuttingEdgeToFindaMidpoint + filamentMinLoadedToMMU;

src/logic/feed_to_bondtech.cpp

@@ -27,8 +27,7 @@ bool FeedToBondtech::Step() {
             dbg_logic_fP(PSTR("Pulley start steps %u"), mm::motion.CurPosition(mm::Pulley));
             state = PushingFilamentToFSensor;
             mm::motion.InitAxis(mm::Pulley);
-            mm::motion.PlanMove<mm::Pulley>(config::defaultBowdenLength, config::pulleyFeedrate); //@@TODO constants - there was some strange acceleration sequence in the original FW,
-            // we can probably hand over some array of constants for hand-tuned acceleration + leverage some smoothing in the stepper as well
+            mm::motion.PlanLongMove<mm::Pulley>(config::defaultBowdenLength, config::pulleyFeedrate, config::pulleySlowFeedrate);
         }
         return false;
     case PushingFilamentToFSensor:

src/modules/motion.h

@@ -162,6 +162,27 @@ public:
             unitToAxisUnit<AxisUnit<steps_t, A, Speed>>(end_rate));
     }
 
+    /// This function exists solely because of some mysterious overflow bug in planning/stepping
+    /// which occurrs when number of steps exceeds 32K. The bug doesn't even exhibit in unit tests :( .
+    /// Therefore it plans multiple segments in case the desired distance is longer than 32K steps.
+    /// So far this is only used for moving the Pulley...
+    template <Axis A, config::UnitBase B>
+    constexpr void PlanLongMove(config::Unit<long double, B, Lenght> delta,
+        config::Unit<long double, B, Speed> feed_rate, config::Unit<long double, B, Speed> end_rate = { 0 }) {
+        auto steps = unitToAxisUnit<AxisUnit<pos_t, A, Lenght>>(delta);
+        while (steps.v > 32767) {
+            PlanMove<A>(
+                { 32767 },
+                unitToAxisUnit<AxisUnit<steps_t, A, Speed>>(feed_rate),
+                unitToAxisUnit<AxisUnit<steps_t, A, Speed>>(feed_rate)); // keep the end feedrate the same to continue with the next segment
+            steps.v -= 32767;
+        }
+        PlanMove<A>( // last segment
+            steps,
+            unitToAxisUnit<AxisUnit<steps_t, A, Speed>>(feed_rate),
+            unitToAxisUnit<AxisUnit<steps_t, A, Speed>>(end_rate));
+    }
+
     /// @returns head position of an axis (last enqueued position)
     /// @param axis axis affected
     pos_t Position(Axis axis) const;

tests/unit/logic/tool_change/test_tool_change.cpp

@@ -39,11 +39,11 @@ void FeedingToBondtech(logic::ToolChange &tc, uint8_t toSlot) {
     REQUIRE(WhileCondition(
         tc,
         [&](int step) -> bool {
-        if(step == 5000){ // on 5000th step make filament sensor trigger
+        if(step == 2000){ // on 5000th step make filament sensor trigger
             mfs::fsensor.ProcessMessage(true);
         }
         return tc.TopLevelState() == ProgressCode::FeedingToBondtech; },
-        200000UL));
+        20000UL));
     REQUIRE(VerifyState(tc, mg::FilamentLoadState::InNozzle, mi::Idler::IdleSlotIndex(), toSlot, true, false, ml::on, ml::off, ErrorCode::OK, ProgressCode::OK));
 }