angle: Initial support for angle sensor calibration
Signed-off-by: Kevin O'Connor <kevin@koconnor.net>
This commit is contained in:
Kevin O'Connor
parent
74937326d3
commit
aec742ece4
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@ -354,7 +354,8 @@ A request may look like:
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and might return:
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`{"id": 123,"result":{"header":["time","angle"]}}`
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and might later produce asynchronous messages such as:
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`{"params":{"errors":0,"data":[[1290.951905,-5063],[1290.952321,-5065]]}}`
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`{"params":{"position_offset":3.151562,"errors":0,
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"data":[[1290.951905,-5063],[1290.952321,-5065]]}}`
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The "header" field in the initial query response is used to describe
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the fields found in later "data" responses.
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@ -4007,6 +4007,7 @@ Magnetic hall angle sensor support for reading stepper motor angle
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shaft measurements using a1333, as5047d, or tle5012b SPI chips. The
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measurements are available via the [API Server](API_Server.md) and
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[motion analysis tool](Debugging.md#motion-analysis-and-data-logging).
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See the [G-Code reference](G-Codes.md#angle) for available commands.
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```
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[angle my_angle_sensor]
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@ -4017,6 +4018,12 @@ sensor_type:
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#sample_period: 0.000400
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# The query period (in seconds) to use during measurements. The
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# default is 0.000400 (which is 2500 samples per second).
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#stepper:
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# The name of the stepper that the angle sensor is attached to (eg,
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# "stepper_x"). Setting this value enables an angle calibration
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# tool. To use this feature, the Python "numpy" package must be
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# installed. The default is to not enable angle calibration for the
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# angle sensor.
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cs_pin:
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# The SPI enable pin for the sensor. This parameter must be provided.
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#spi_speed:
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@ -106,6 +106,27 @@ VAL=<value>`: Writes raw "value" into a register "register". Both
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"value" and "register" can be a decimal or a hexadecimal integer. Use
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with care, and refer to ADXL345 data sheet for the reference.
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### [angle]
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The following commands are available when an
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[angle config section](Config_Reference.md#angle) is enabled.
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#### ANGLE_CALIBRATE
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`ANGLE_CALIBRATE CHIP=<chip_name>`: Perform angle calibration on the
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given sensor (there must be an `[angle chip_name]` config section that
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has specified a `stepper` parameter). IMPORTANT - this tool will
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command the stepper motor to move without checking the normal
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kinematic boundary limits. Ideally the motor should be disconnected
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from any printer carriage before performing calibration. If the
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stepper can not be disconnected from the printer, make sure the
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carriage is near the center of its rail before starting calibration.
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(The stepper motor may move forwards or backwards two full rotations
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during this test.) After completing this test use the `SAVE_CONFIG`
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command to save the calibration data to the config file. In order to
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use this tool the Python "numpy" package must be installed (see the
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[measuring resonance document](Measuring_Resonances.md#software-installation)
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for more information).
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### [bed_mesh]
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The following commands are available when the
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@ -3,12 +3,261 @@
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# Copyright (C) 2021,2022 Kevin O'Connor <kevin@koconnor.net>
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#
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# This file may be distributed under the terms of the GNU GPLv3 license.
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import logging, threading
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import logging, math, threading
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from . import bus, motion_report
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MIN_MSG_TIME = 0.100
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TCODE_ERROR = 0xff
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TRINAMIC_DRIVERS = ["tmc2130", "tmc2208", "tmc2209", "tmc2660", "tmc5160"]
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CALIBRATION_BITS = 6 # 64 entries
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ANGLE_BITS = 16 # angles range from 0..65535
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class AngleCalibration:
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def __init__(self, config):
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self.printer = config.get_printer()
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self.name = config.get_name()
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self.stepper_name = config.get('stepper', None)
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if self.stepper_name is None:
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# No calibration
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return
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try:
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import numpy
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except:
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raise config.error("Angle calibration requires numpy module")
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sconfig = config.getsection(self.stepper_name)
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sconfig.getint('microsteps', note_valid=False)
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self.tmc_module = self.mcu_stepper = None
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# Current calibration data
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self.mcu_pos_offset = None
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self.angle_phase_offset = 0.
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self.calibration_reversed = False
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self.calibration = []
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cal = config.get('calibrate', None)
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if cal is not None:
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data = [d.strip() for d in cal.split(',')]
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angles = [float(d) for d in data if d]
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self.load_calibration(angles)
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# Register commands
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self.printer.register_event_handler("stepper:sync_mcu_position",
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self.handle_sync_mcu_pos)
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self.printer.register_event_handler("klippy:connect", self.connect)
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cname = self.name.split()[-1]
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gcode = self.printer.lookup_object('gcode')
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gcode.register_mux_command("ANGLE_CALIBRATE", "CHIP",
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cname, self.cmd_ANGLE_CALIBRATE,
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desc=self.cmd_ANGLE_CALIBRATE_help)
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def handle_sync_mcu_pos(self, mcu_stepper):
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if mcu_stepper.get_name() == self.stepper_name:
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self.mcu_pos_offset = None
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def calc_mcu_pos_offset(self, sample):
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# Lookup phase information
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mcu_phase_offset, phases = self.tmc_module.get_phase_offset()
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if mcu_phase_offset is None:
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return
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# Find mcu position at time of sample
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angle_time, angle_pos = sample
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mcu_pos = self.mcu_stepper.get_past_mcu_position(angle_time)
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# Convert angle_pos to mcu_pos units
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microsteps, full_steps = self.get_microsteps()
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angle_to_mcu_pos = full_steps * microsteps / float(1<<ANGLE_BITS)
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angle_mpos = angle_pos * angle_to_mcu_pos
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# Calculate adjustment for stepper phases
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phase_diff = ((angle_mpos + self.angle_phase_offset * angle_to_mcu_pos)
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- (mcu_pos + mcu_phase_offset)) % phases
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if phase_diff > phases//2:
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phase_diff -= phases
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# Store final offset
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self.mcu_pos_offset = mcu_pos - (angle_mpos - phase_diff)
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def apply_calibration(self, samples):
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calibration = self.calibration
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if not calibration:
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return None
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calibration_reversed = self.calibration_reversed
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interp_bits = ANGLE_BITS - CALIBRATION_BITS
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interp_mask = (1 << interp_bits) - 1
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interp_round = 1 << (interp_bits - 1)
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for i, (samp_time, angle) in enumerate(samples):
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bucket = (angle & 0xffff) >> interp_bits
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cal1 = calibration[bucket]
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cal2 = calibration[bucket + 1]
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adj = (angle & interp_mask) * (cal2 - cal1)
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adj = cal1 + ((adj + interp_round) >> interp_bits)
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angle_diff = (angle - adj) & 0xffff
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angle_diff -= (angle_diff & 0x8000) << 1
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new_angle = angle - angle_diff
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if calibration_reversed:
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new_angle = -new_angle
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samples[i] = (samp_time, new_angle)
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if self.mcu_pos_offset is None:
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self.calc_mcu_pos_offset(samples[0])
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if self.mcu_pos_offset is None:
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return None
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return self.mcu_stepper.mcu_to_commanded_position(self.mcu_pos_offset)
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def load_calibration(self, angles):
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# Calculate linear intepolation calibration buckets by solving
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# linear equations
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angle_max = 1 << ANGLE_BITS
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calibration_count = 1 << CALIBRATION_BITS
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bucket_size = angle_max // calibration_count
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full_steps = len(angles)
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nominal_step = float(angle_max) / full_steps
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self.angle_phase_offset = (angles.index(min(angles)) & 3) * nominal_step
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self.calibration_reversed = angles[-2] > angles[-1]
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if self.calibration_reversed:
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angles = list(reversed(angles))
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first_step = angles.index(min(angles))
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angles = angles[first_step:] + angles[:first_step]
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import numpy
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eqs = numpy.zeros((full_steps, calibration_count))
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ans = numpy.zeros((full_steps,))
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for step, angle in enumerate(angles):
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int_angle = int(angle + .5) % angle_max
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bucket = int(int_angle / bucket_size)
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bucket_start = bucket * bucket_size
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ang_diff = angle - bucket_start
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ang_diff_per = ang_diff / bucket_size
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eq = eqs[step]
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eq[bucket] = 1. - ang_diff_per
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eq[(bucket + 1) % calibration_count] = ang_diff_per
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ans[step] = float(step * nominal_step)
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if bucket + 1 >= calibration_count:
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ans[step] -= ang_diff_per * angle_max
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sol = numpy.linalg.lstsq(eqs, ans, rcond=None)[0]
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isol = [int(s + .5) for s in sol]
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self.calibration = isol + [isol[0] + angle_max]
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def lookup_tmc(self):
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for driver in TRINAMIC_DRIVERS:
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driver_name = "%s %s" % (driver, self.stepper_name)
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module = self.printer.lookup_object(driver_name, None)
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if module is not None:
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return module
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raise self.printer.command_error("Unable to find TMC driver for %s"
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% (self.stepper_name,))
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def connect(self):
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self.tmc_module = self.lookup_tmc()
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fmove = self.printer.lookup_object('force_move')
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self.mcu_stepper = fmove.lookup_stepper(self.stepper_name)
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def get_microsteps(self):
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configfile = self.printer.lookup_object('configfile')
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sconfig = configfile.get_status(None)['settings']
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stconfig = sconfig.get(self.stepper_name, {})
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microsteps = stconfig['microsteps']
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full_steps = stconfig['full_steps_per_rotation']
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return microsteps, full_steps
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def get_stepper_phase(self):
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mcu_phase_offset, phases = self.tmc_module.get_phase_offset()
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if mcu_phase_offset is None:
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raise self.printer.command_error("Driver phase not known for %s"
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% (self.stepper_name,))
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mcu_pos = self.mcu_stepper.get_mcu_position()
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return (mcu_pos + mcu_phase_offset) % phases
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def do_calibration_moves(self):
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move = self.printer.lookup_object('force_move').manual_move
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# Start data collection
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angle_sensor = self.printer.lookup_object(self.name)
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cconn = angle_sensor.start_internal_client()
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# Move stepper several turns (to allow internal sensor calibration)
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microsteps, full_steps = self.get_microsteps()
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mcu_stepper = self.mcu_stepper
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step_dist = mcu_stepper.get_step_dist()
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full_step_dist = step_dist * microsteps
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rotation_dist = full_steps * full_step_dist
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align_dist = step_dist * self.get_stepper_phase()
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move_time = 0.010
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move_speed = full_step_dist / move_time
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move(mcu_stepper, -(rotation_dist+align_dist), move_speed)
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move(mcu_stepper, 2. * rotation_dist, move_speed)
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move(mcu_stepper, -2. * rotation_dist, move_speed)
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move(mcu_stepper, .5 * rotation_dist - full_step_dist, move_speed)
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# Move to each full step position
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toolhead = self.printer.lookup_object('toolhead')
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times = []
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samp_dist = full_step_dist
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for i in range(2 * full_steps):
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move(mcu_stepper, samp_dist, move_speed)
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start_query_time = toolhead.get_last_move_time() + 0.050
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end_query_time = start_query_time + 0.050
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times.append((start_query_time, end_query_time))
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toolhead.dwell(0.150)
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if i == full_steps-1:
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# Reverse direction and test each full step again
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move(mcu_stepper, .5 * rotation_dist, move_speed)
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move(mcu_stepper, -.5 * rotation_dist + samp_dist, move_speed)
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samp_dist = -samp_dist
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move(mcu_stepper, .5*rotation_dist + align_dist, move_speed)
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toolhead.wait_moves()
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# Finish data collection
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cconn.finalize()
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msgs = cconn.get_messages()
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# Correlate query responses
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cal = {}
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step = 0
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for msg in msgs:
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for query_time, pos in msg['params']['data']:
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# Add to step tracking
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while step < len(times) and query_time > times[step][1]:
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step += 1
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if step < len(times) and query_time >= times[step][0]:
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cal.setdefault(step, []).append(pos)
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if len(cal) != len(times):
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raise self.printer.command_error(
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"Failed calibration - incomplete sensor data")
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fcal = { i: cal[i] for i in range(full_steps) }
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rcal = { full_steps-i-1: cal[i+full_steps] for i in range(full_steps) }
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return fcal, rcal
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def calc_angles(self, meas):
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total_count = total_variance = 0
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angles = {}
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for step, data in meas.items():
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count = len(data)
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angle_avg = float(sum(data)) / count
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angles[step] = angle_avg
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total_count += count
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total_variance += sum([(d - angle_avg)**2 for d in data])
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return angles, math.sqrt(total_variance / total_count), total_count
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cmd_ANGLE_CALIBRATE_help = "Calibrate angle sensor to stepper motor"
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def cmd_ANGLE_CALIBRATE(self, gcmd):
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# Perform calibration movement and capture
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old_calibration = self.calibration
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self.calibration = []
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try:
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fcal, rcal = self.do_calibration_moves()
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finally:
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self.calibration = old_calibration
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# Calculate each step position average and variance
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microsteps, full_steps = self.get_microsteps()
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fangles, fstd, ftotal = self.calc_angles(fcal)
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rangles, rstd, rtotal = self.calc_angles(rcal)
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if (len({a: i for i, a in fangles.items()}) != len(fangles)
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or len({a: i for i, a in rangles.items()}) != len(rangles)):
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raise self.printer.command_error(
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"Failed calibration - sensor not updating for each step")
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merged = { i: fcal[i] + rcal[i] for i in range(full_steps) }
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angles, std, total = self.calc_angles(merged)
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gcmd.respond_info("angle: stddev=%.3f (%.3f forward / %.3f reverse)"
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" in %d queries" % (std, fstd, rstd, total))
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# Order data with lowest/highest magnet position first
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anglist = [angles[i] % 0xffff for i in range(full_steps)]
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if angles[0] > angles[1]:
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first_ang = max(anglist)
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else:
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first_ang = min(anglist)
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first_phase = anglist.index(first_ang) & ~3
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anglist = anglist[first_phase:] + anglist[:first_phase]
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# Save results
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cal_contents = []
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for i, angle in enumerate(anglist):
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if not i % 8:
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cal_contents.append('\n')
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cal_contents.append("%.1f" % (angle,))
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cal_contents.append(',')
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cal_contents.pop()
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configfile = self.printer.lookup_object('configfile')
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configfile.remove_section(self.name)
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configfile.set(self.name, 'calibrate', ''.join(cal_contents))
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class HelperA1333:
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SPI_MODE = 3
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SPI_SPEED = 10000000
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@ -51,6 +300,7 @@ class Angle:
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self.printer = config.get_printer()
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self.sample_period = config.getfloat('sample_period', SAMPLE_PERIOD,
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above=0.)
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self.calibration = AngleCalibration(config)
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# Measurement conversion
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self.start_clock = self.time_shift = self.sample_ticks = 0
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self.last_sequence = self.last_angle = 0
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@ -148,7 +398,9 @@ class Angle:
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samples, error_count = self._extract_samples(raw_samples)
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if not samples:
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return {}
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return {'data': samples, 'errors': error_count}
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offset = self.calibration.apply_calibration(samples)
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return {'data': samples, 'errors': error_count,
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'position_offset': offset}
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def _start_measurements(self):
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if self.is_measuring():
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return
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@ -183,6 +435,8 @@ class Angle:
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self.api_dump.add_client(web_request)
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hdr = ('time', 'angle')
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web_request.send({'header': hdr})
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def start_internal_client(self):
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return self.api_dump.add_internal_client()
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def load_config_prefix(config):
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return Angle(config)
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