extruder: Create a new class and python file to track the printer extruder

Create a new python file (extruder.py) to control the extruder heater
and stepper motors.  This separates the extruder control logic from
the cartesian robot code - making it easier to customize both the
kinematic control of the robot as well as the extruder.

Signed-off-by: Kevin O'Connor <kevin@koconnor.net>

config/avrsim.cfg

@@ -42,7 +42,7 @@ position_min: 0.1
 position_endstop: 0.5
 position_max: 200
 
-[stepper_e]
+[extruder]
 # Pins: PC3, PC2
 step_pin: ar19
 dir_pin: ar18
@@ -50,8 +50,6 @@ enable_pin: ar25
 step_distance: .004242
 max_velocity: 200000
 max_accel: 3000
-
-[heater_nozzle]
 heater_pin: ar4
 thermistor_pin: analog1
 thermistor_type: EPCOS 100K B57560G104F

config/example.cfg

@@ -77,19 +77,19 @@ position_min: 0.1
 position_endstop: 0.5
 position_max: 200
 
-# The stepper_e section is used to describe the stepper controlling
+# The extruder section is used to describe both the stepper
-# the printer extruder. It has the same settings as the stepper_x
+# controlling the printer extruder and the heater parameters for the
-# section
+# nozzle. The stepper configuration has the same settings as the
-[stepper_e]
+# stepper_x section and the heater configuration has the same settings
+# as the heater_bed section
+[extruder]
 step_pin: ar19
 dir_pin: ar18
 enable_pin: !ar25
 step_distance: .004242
 max_velocity: 200000
 max_accel: 3000
-
+# The remaining variables describe the extruder heater
-# The heater_nozzle section describes the extruder and extruder heater
-[heater_nozzle]
 heater_pin: ar4
 #   PWM output pin controlling the heater
 thermistor_pin: analog1
@@ -118,8 +118,7 @@ max_temp: 210
 #   this value)
 
 # The heater_bed section describes a heated bed (if present - omit
-# section if not present). It has the same settings as the
+# section if not present).
-# heater_nozzle section
 [heater_bed]
 heater_pin: ar3
 thermistor_pin: analog0

config/makergear-m2-2012.cfg

@@ -43,15 +43,13 @@ position_min: 0.1
 position_endstop: 0.7
 position_max: 200
 
-[stepper_e]
+[extruder]
 step_pin: PC3
 dir_pin: !PL6
 enable_pin: !PA4
 step_distance: .004242
 max_velocity: 200000
 max_accel: 3000
-
-[heater_nozzle]
 heater_pin: PH6
 thermistor_pin: PF0
 thermistor_type: EPCOS 100K B57560G104F

klippy/cartesian.py

@@ -6,14 +6,14 @@
 import logging
 import stepper, homing
 
-StepList = (0, 1, 2, 3)
+StepList = (0, 1, 2)
 
 class CartKinematics:
     def __init__(self, printer, config):
-        steppers = ['stepper_x', 'stepper_y', 'stepper_z', 'stepper_e']
+        steppers = ['stepper_x', 'stepper_y', 'stepper_z']
         self.steppers = [stepper.PrinterStepper(printer, config.getsection(n))
                          for n in steppers]
-        self.stepper_pos = [0, 0, 0, 0]
+        self.stepper_pos = [0, 0, 0]
     def build_config(self):
         for stepper in self.steppers:
             stepper.build_config()
@@ -31,9 +31,6 @@ class CartKinematics:
         accel_factor = min([self.steppers[i].max_accel / abs(axes_d[i])
                             for i in StepList if axes_d[i]])
         return velocity_factor * move_d, accel_factor * move_d
-    def get_max_e_speed(self):
-        s = self.steppers[3]
-        return s.max_velocity, s.max_accel
     def home(self, toolhead, axis):
         # Each axis is homed independently and in order
         homing_state = homing.Homing(toolhead, self.steppers) # XXX

klippy/extruder.py

@@ -0,0 +1,62 @@
+# Code for handling printer nozzle extruders
+#
+# Copyright (C) 2016  Kevin O'Connor <kevin@koconnor.net>
+#
+# This file may be distributed under the terms of the GNU GPLv3 license.
+import logging
+import stepper, heater
+
+class PrinterExtruder:
+    def __init__(self, printer, config):
+        cfg = config.getsection('extruder')
+        self.heater = heater.PrinterHeater(printer, cfg)
+        self.stepper = stepper.PrinterStepper(printer, cfg)
+        self.stepper_pos = 0
+    def build_config(self):
+        self.heater.build_config()
+        self.stepper.build_config()
+    def get_max_speed(self):
+        return self.stepper.max_velocity, self.stepper.max_accel
+    def motor_off(self, move_time):
+        self.stepper.motor_enable(move_time, 0)
+    def move(self, move_time, move):
+        inv_accel = 1. / move.accel
+        new_step_pos = int(move.pos[3]*self.stepper.inv_step_dist + 0.5)
+        steps = new_step_pos - self.stepper_pos
+        if not steps:
+            return
+        self.stepper_pos = new_step_pos
+        sdir = 0
+        if steps < 0:
+            sdir = 1
+            steps = -steps
+        clock_offset, clock_freq, so = self.stepper.prep_move(sdir, move_time)
+
+        step_dist = move.move_d / steps
+        step_offset = 0.5
+
+        # Acceleration steps
+        #t = sqrt(2*pos/accel + (start_v/accel)**2) - start_v/accel
+        accel_clock_offset = move.start_v * inv_accel * clock_freq
+        accel_sqrt_offset = accel_clock_offset**2
+        accel_multiplier = 2.0 * step_dist * inv_accel * clock_freq**2
+        accel_steps = move.accel_r * steps
+        step_offset = so.step_sqrt(
+            accel_steps, step_offset, clock_offset - accel_clock_offset
+            , accel_sqrt_offset, accel_multiplier)
+        clock_offset += move.accel_t * clock_freq
+        # Cruising steps
+        #t = pos/cruise_v
+        cruise_multiplier = step_dist * clock_freq / move.cruise_v
+        cruise_steps = move.cruise_r * steps
+        step_offset = so.step_factor(
+            cruise_steps, step_offset, clock_offset, cruise_multiplier)
+        clock_offset += move.cruise_t * clock_freq
+        # Deceleration steps
+        #t = cruise_v/accel - sqrt((cruise_v/accel)**2 - 2*pos/accel)
+        decel_clock_offset = move.cruise_v * inv_accel * clock_freq
+        decel_sqrt_offset = decel_clock_offset**2
+        decel_steps = move.decel_r * steps
+        so.step_sqrt(
+            decel_steps, step_offset, clock_offset + decel_clock_offset
+            , decel_sqrt_offset, -accel_multiplier)

klippy/gcode.py

@@ -35,7 +35,10 @@ class GCodeParser:
         self.axis2pos = {'X': 0, 'Y': 1, 'Z': 2, 'E': 3}
     def build_config(self):
         self.toolhead = self.printer.objects['toolhead']
-        self.heater_nozzle = self.printer.objects.get('heater_nozzle')
+        self.heater_nozzle = None
+        extruder = self.printer.objects.get('extruder')
+        if extruder:
+            self.heater_nozzle = extruder.heater
         self.heater_bed = self.printer.objects.get('heater_bed')
         self.fan = self.printer.objects.get('fan')
         self.build_handlers()

klippy/klippy.py

@@ -5,7 +5,7 @@
 #
 # This file may be distributed under the terms of the GNU GPLv3 license.
 import sys, optparse, ConfigParser, logging, time, threading
-import gcode, toolhead, util, mcu, fan, heater, reactor
+import gcode, toolhead, util, mcu, fan, heater, extruder, reactor
 
 class ConfigWrapper:
     def __init__(self, printer, section):
@@ -52,9 +52,9 @@ class Printer:
         if self.fileconfig.has_section('fan'):
             self.objects['fan'] = fan.PrinterFan(
                 self, ConfigWrapper(self, 'fan'))
-        if self.fileconfig.has_section('heater_nozzle'):
+        if self.fileconfig.has_section('extruder'):
-            self.objects['heater_nozzle'] = heater.PrinterHeater(
+            self.objects['extruder'] = extruder.PrinterExtruder(
-                self, ConfigWrapper(self, 'heater_nozzle'))
+                self, ConfigWrapper(self, 'extruder'))
         if self.fileconfig.has_section('heater_bed'):
             self.objects['heater_bed'] = heater.PrinterHeater(
                 self, ConfigWrapper(self, 'heater_bed'))

klippy/toolhead.py

@@ -61,6 +61,8 @@ class Move:
         # Generate step times for the move
         next_move_time = self.toolhead.get_next_move_time()
         self.toolhead.kin.move(next_move_time, self)
+        if self.axes_d[3]:
+            self.toolhead.extruder.move(next_move_time, self)
         self.toolhead.update_move_time(accel_t + cruise_t + decel_t)
 
 # Class to track a list of pending move requests and to facilitate
@@ -113,6 +115,7 @@ class ToolHead:
     def __init__(self, printer, config):
         self.printer = printer
         self.reactor = printer.reactor
+        self.extruder = printer.objects.get('extruder')
         self.kin = cartesian.CartKinematics(printer, config)
         self.max_xy_speed, self.max_xy_accel = self.kin.get_max_xy_speed()
         self.junction_deviation = config.getfloat('junction_deviation', 0.02)
@@ -208,7 +211,7 @@ class ToolHead:
         move.process(0., 0.)
     def _move_only_e(self, newpos, axes_d, speed):
         self.move_queue.flush()
-        kin_speed, kin_accel = self.kin.get_max_e_speed()
+        kin_speed, kin_accel = self.extruder.get_max_speed()
         speed = min(speed, self.max_xy_speed, kin_speed)
         accel = min(self.max_xy_accel, kin_accel)
         move = Move(self, newpos, abs(axes_d[3]), axes_d, speed, accel)
@@ -238,5 +241,6 @@ class ToolHead:
         self.dwell(STALL_TIME)
         last_move_time = self.get_last_move_time()
         self.kin.motor_off(last_move_time)
+        self.extruder.motor_off(last_move_time)
         self.dwell(STALL_TIME)
         logging.debug('; Max time of %f' % (last_move_time,))