Detect stallguard on Selector+Idler - report MOVE_FAILED

src/logic/command_base.cpp

@@ -13,11 +13,11 @@
 
 namespace logic {
 
-inline ErrorCode &operator|=(ErrorCode &a, ErrorCode b) {
+constexpr ErrorCode &operator|=(ErrorCode &a, ErrorCode b) {
     return a = (ErrorCode)((uint16_t)a | (uint16_t)b);
 }
 
-static ErrorCode TMC2130ToErrorCode(const hal::tmc2130::ErrorFlags &ef) {
+constexpr ErrorCode TMC2130ToErrorCode(const hal::tmc2130::ErrorFlags &ef) {
     ErrorCode e = ErrorCode::RUNNING;
 
     if (ef.reset_flag) {
@@ -39,7 +39,7 @@ static ErrorCode TMC2130ToErrorCode(const hal::tmc2130::ErrorFlags &ef) {
     return e;
 }
 
-static ErrorCode AddErrorAxisBit(ErrorCode ec, uint8_t tmcIndex) {
+constexpr ErrorCode AddErrorAxisBit(ErrorCode ec, uint8_t tmcIndex) {
     switch (tmcIndex) {
     case config::Axis::Pulley:
         ec |= ErrorCode::TMC_PULLEY_BIT;
@@ -61,12 +61,14 @@ ErrorCode CheckMovable(mm::MovableBase &m) {
     case mm::MovableBase::TMCFailed:
         return AddErrorAxisBit(TMC2130ToErrorCode(m.TMCErrorFlags()), m.Axis());
     case mm::MovableBase::HomingFailed:
-        return AddErrorAxisBit(ErrorCode::HOMING_FAILED, m.Axis());
+        return m.SupportsHoming() ? AddErrorAxisBit(ErrorCode::HOMING_FAILED, m.Axis()) : ErrorCode::RUNNING;
+    case mm::MovableBase::MoveFailed:
+        return m.SupportsHoming() ? AddErrorAxisBit(ErrorCode::MOVE_FAILED, m.Axis()) : ErrorCode::RUNNING;
     }
     return ErrorCode::RUNNING;
 }
 
-static inline ErrorCode WithoutAxisBits(ErrorCode ec) {
+constexpr ErrorCode WithoutAxisBits(ErrorCode ec) {
     return static_cast<ErrorCode>(
         static_cast<uint16_t>(ec)
         & (~(static_cast<uint16_t>(ErrorCode::TMC_SELECTOR_BIT)
@@ -93,19 +95,35 @@ bool CommandBase::WaitForOneModuleErrorRecovery(ErrorCode ec, modules::motion::M
         }
 
         switch (state) {
-        case ProgressCode::ERRWaitingForUser: // waiting for a recovery - mask axis bits:
+        case ProgressCode::ERRWaitingForUser: { // waiting for a recovery - mask axis bits:
-            if (WithoutAxisBits(ec) == ErrorCode::HOMING_FAILED) {
+            mui::Event ev = mui::userInput.ConsumeEvent();
-                // homing can be recovered
+            if (ev == mui::Event::Middle) {
-                mui::Event ev = mui::userInput.ConsumeEvent();
+                switch (WithoutAxisBits(ec)) {
-                if (ev == mui::Event::Middle) {
+                case ErrorCode::MOVE_FAILED:
-                    recoveringMovableErrorAxisMask |= axisMask;
+                    // A failed move can be recovered for Idler and Selector (doesn't make sense on the Pulley).
-                    m.PlanHome(); // force initiate a new homing attempt
+                    // But - force initiate a new homing attempt of BOTH Idler and Selector (that's the main difference from HomingFailed)
+                    // because we expect the user disassembled the whole MMU to remove a stuck piece of filament
+                    // and therefore we cannot rely on Idler's and Selector's position
+                    recoveringMovableErrorAxisMask |= 0x3; // @@TODO better axis masks
+                    mi::idler.PlanHome();
+                    ms::selector.PlanHome();
                     state = ProgressCode::Homing;
                     error = ErrorCode::RUNNING;
+                    break;
+                case ErrorCode::HOMING_FAILED:
+                    // A failed homing can be recovered
+                    recoveringMovableErrorAxisMask |= axisMask;
+                    m.PlanHome(); // force initiate a new homing attempt just on the failed axis
+                    state = ProgressCode::Homing;
+                    error = ErrorCode::RUNNING;
+                    break;
+                default:
+                    break;
                 }
             }
             // TMC errors cannot be recovered safely, waiting for power cycling the MMU
             return true;
+        }
         default:
             return true; // prevent descendant from taking over while in an error state
         }

src/logic/error_codes.h

@@ -46,6 +46,11 @@ enum class ErrorCode : uint_fast16_t {
     ///< - a piece of filament was left inside - pushed in front of the loaded filament causing the fsensor trigger too early
     ///< - fsensor is faulty producing bogus triggers
 
+    MOVE_FAILED = 0x800a, ///< generic move failed error - always reported with the corresponding axis bit set (Idler or Selector) as follows:
+    MOVE_SELECTOR_FAILED = MOVE_FAILED | TMC_SELECTOR_BIT, ///< E32905 the Selector was unable to move to desired position properly - that means something is blocking its movement, e.g. a piece of filament got out of pulley body
+    MOVE_IDLER_FAILED = MOVE_FAILED | TMC_IDLER_BIT, ///< E33033 the Idler was unable to move - unused at the time of creation, but added for completeness
+    MOVE_PULLEY_FAILED = MOVE_FAILED | TMC_PULLEY_BIT, ///< E32841 the Pulley was unable to move - unused at the time of creation, but added for completeness
+
     QUEUE_FULL = 0x802b, ///< E32811 internal logic error - attempt to move with a full queue
 
     VERSION_MISMATCH = 0x802c, ///< E32812 internal error of the printer - incompatible version of the MMU FW

src/modules/idler.h

@@ -51,6 +51,8 @@ public:
     /// - blocked -> set idler's position according to the active filament slot
     void Init();
 
+    virtual bool SupportsHoming() override { return true; }
+
 protected:
     virtual void PrepareMoveToPlannedSlot() override;
     virtual void PlanHomingMoveForward() override;

src/modules/movable_base.cpp

@@ -36,6 +36,13 @@ void MovableBase::PerformMove() {
         // TMC2130 entered some error state, the planned move couldn't have been finished - result of operation is Failed
         tmcErrorFlags = mm::motion.DriverForAxis(axis).GetErrorFlags(); // save the failed state
         state = TMCFailed;
+    } else if (mm::motion.StallGuard(axis) && SupportsHoming()) {
+        // Axis stalled while moving - dangerous especially with the Selector
+        // Checked only for axes which support homing (because we plan a homing move after the error is resolved to regain precise position)
+        mm::motion.StallGuardReset(axis);
+        mm::motion.AbortPlannedMoves(axis, true);
+        // @@TODO move a bit back from where it came from to enable easier removal of whatever is blocking the axis
+        state = MoveFailed;
     } else if (mm::motion.QueueEmpty(axis)) {
         // move finished
         currentSlot = plannedSlot;

src/modules/movable_base.h

@@ -17,7 +17,8 @@ public:
         HomeForward,
         HomeBack,
         TMCFailed,
-        HomingFailed
+        HomingFailed,
+        MoveFailed,
     };
 
     /// Operation (Engage/Disengage/MoveToSlot) return values
@@ -67,6 +68,8 @@ public:
 
     inline config::Axis Axis() const { return axis; }
 
+    virtual bool SupportsHoming() = 0;
+
 protected:
     /// internal state of the automaton
     uint8_t state;

src/modules/pulley.h

@@ -34,6 +34,8 @@ public:
     void InitAxis();
     void Disable();
 
+    virtual bool SupportsHoming() override { return false; }
+
 protected:
     virtual void PrepareMoveToPlannedSlot() override {}
     virtual void PlanHomingMoveForward() override {}

src/modules/selector.h

@@ -40,6 +40,8 @@ public:
     /// - blocked -> set selector's position according to the active filament slot
     void Init();
 
+    virtual bool SupportsHoming() override { return true; }
+
 protected:
     virtual void PrepareMoveToPlannedSlot() override;
     virtual void PlanHomingMoveForward() override;