⚡️ Fix and improve Inline Laser Power (#22690)

Author: descipher

Marlin/Configuration_adv.h

@@ -3475,7 +3475,7 @@
                                                // ESP32: If SPINDLE_LASER_PWM_PIN is onboard then <=78125Hz. For I2S expander
                                                //  the frequency determines the PWM resolution. 2500Hz = 0-100, 977Hz = 0-255, ...
                                                //  (250000 / SPINDLE_LASER_FREQUENCY) = max value.
-#endif
+  #endif
 
   //#define AIR_EVACUATION                     // Cutter Vacuum / Laser Blower motor control with G-codes M10-M11
   #if ENABLED(AIR_EVACUATION)
@@ -3548,8 +3548,11 @@
     #endif
 
     // Define the minimum and maximum test pulse time values for a laser test fire function
-    #define LASER_TEST_PULSE_MIN           1   // Used with Laser Control Menu
-    #define LASER_TEST_PULSE_MAX         999   // Caution: Menu may not show more than 3 characters
+    #define LASER_TEST_PULSE_MIN           1   // (ms) Used with Laser Control Menu
+    #define LASER_TEST_PULSE_MAX         999   // (ms) Caution: Menu may not show more than 3 characters
+
+    #define SPINDLE_LASER_POWERUP_DELAY   50   // (ms) Delay to allow the spindle/laser to come up to speed/power
+    #define SPINDLE_LASER_POWERDOWN_DELAY 50   // (ms) Delay to allow the spindle to stop
 
    /**
     * Laser Safety Timeout
@@ -3562,79 +3565,38 @@
     #define LASER_SAFETY_TIMEOUT_MS     1000   // (ms)
 
     /**
-     * Enable inline laser power to be handled in the planner / stepper routines.
-     * Inline power is specified by the I (inline) flag in an M3 command (e.g., M3 S20 I)
-     * or by the 'S' parameter in G0/G1/G2/G3 moves (see LASER_MOVE_POWER).
+     * Any M3 or G1/2/3/5 command with the 'I' parameter enables continuous inline power mode.
+     *
+     * e.g., 'M3 I' enables continuous inline power which is processed by the planner.
+     * Power is stored in move blocks and applied when blocks are processed by the Stepper ISR.
+     *
+     * 'M4 I' sets dynamic mode which uses the current feedrate to calculate a laser power OCR value.
      *
-     * This allows the laser to keep in perfect sync with the planner and removes
-     * the powerup/down delay since lasers require negligible time.
+     * Any move in dynamic mode will use the current feedrate to calculate the laser power.
+     * Feed rates are set by the F parameter of a move command e.g. G1 X0 Y10 F6000
+     * Laser power would be calculated by bit shifting off 8 LSB's. In binary this is div 256.
+     * The calculation gives us ocr values from 0 to 255, values over F65535 will be set as 255 .
+     * More refined power control such as compesation for accell/decell will be addressed in future releases.
+     *
+     * M5 I clears inline mode and set power to 0, M5 sets the power output to 0 but leaves inline mode on.
      */
-    //#define LASER_POWER_INLINE
-
-    #if ENABLED(LASER_POWER_INLINE)
-      /**
-       * Scale the laser's power in proportion to the movement rate.
-       *
-       * - Sets the entry power proportional to the entry speed over the nominal speed.
-       * - Ramps the power up every N steps to approximate the speed trapezoid.
-       * - Due to the limited power resolution this is only approximate.
-       */
-      #define LASER_POWER_INLINE_TRAPEZOID
-
-      /**
-       * Continuously calculate the current power (nominal_power * current_rate / nominal_rate).
-       * Required for accurate power with non-trapezoidal acceleration (e.g., S_CURVE_ACCELERATION).
-       * This is a costly calculation so this option is discouraged on 8-bit AVR boards.
-       *
-       * LASER_POWER_INLINE_TRAPEZOID_CONT_PER defines how many step cycles there are between power updates. If your
-       * board isn't able to generate steps fast enough (and you are using LASER_POWER_INLINE_TRAPEZOID_CONT), increase this.
-       * Note that when this is zero it means it occurs every cycle; 1 means a delay wait one cycle then run, etc.
-       */
-      //#define LASER_POWER_INLINE_TRAPEZOID_CONT
-
-      /**
-       * Stepper iterations between power updates. Increase this value if the board
-       * can't keep up with the processing demands of LASER_POWER_INLINE_TRAPEZOID_CONT.
-       * Disable (or set to 0) to recalculate power on every stepper iteration.
-       */
-      //#define LASER_POWER_INLINE_TRAPEZOID_CONT_PER 10
-
-      /**
-       * Include laser power in G0/G1/G2/G3/G5 commands with the 'S' parameter
-       */
-      //#define LASER_MOVE_POWER
 
-      #if ENABLED(LASER_MOVE_POWER)
-        // Turn off the laser on G0 moves with no power parameter.
-        // If a power parameter is provided, use that instead.
-        //#define LASER_MOVE_G0_OFF
-
-        // Turn off the laser on G28 homing.
-        //#define LASER_MOVE_G28_OFF
-      #endif
-
-      /**
-       * Inline flag inverted
-       *
-       * WARNING: M5 will NOT turn off the laser unless another move
-       *          is done (so G-code files must end with 'M5 I').
-       */
-      //#define LASER_POWER_INLINE_INVERT
-
-      /**
-       * Continuously apply inline power. ('M3 S3' == 'G1 S3' == 'M3 S3 I')
-       *
-       * The laser might do some weird things, so only enable this
-       * feature if you understand the implications.
-       */
-      //#define LASER_POWER_INLINE_CONTINUOUS
-
-    #else
-
-      #define SPINDLE_LASER_POWERUP_DELAY     50 // (ms) Delay to allow the spindle/laser to come up to speed/power
-      #define SPINDLE_LASER_POWERDOWN_DELAY   50 // (ms) Delay to allow the spindle to stop
+    /**
+     * Enable M3 commands for laser mode inline power planner syncing.
+     * This feature enables any M3 S-value to be injected into the block buffers while in
+     * CUTTER_MODE_CONTINUOUS. The option allows M3 laser power to be commited without waiting
+     * for a planner syncronization
+     */
+    //#define LASER_POWER_SYNC
 
-    #endif
+    /**
+     * Scale the laser's power in proportion to the movement rate.
+     *
+     * - Sets the entry power proportional to the entry speed over the nominal speed.
+     * - Ramps the power up every N steps to approximate the speed trapezoid.
+     * - Due to the limited power resolution this is only approximate.
+     */
+    //#define LASER_POWER_TRAP
 
     //
     // Laser I2C Ammeter (High precision INA226 low/high side module)

Marlin/src/feature/spindle_laser.cpp

@@ -39,18 +39,26 @@
 #endif
 
 SpindleLaser cutter;
-uint8_t SpindleLaser::power,
+bool SpindleLaser::enable_state;                                      // Virtual enable state, controls enable pin if present and or apply power if > 0
+uint8_t SpindleLaser::power,                                          // Actual power output 0-255 ocr or "0 = off" > 0 = "on"
         SpindleLaser::last_power_applied; // = 0                      // Basic power state tracking
+
 #if ENABLED(LASER_FEATURE)
-  cutter_test_pulse_t SpindleLaser::testPulse = 50;                   // Test fire Pulse time ms value.
+  cutter_test_pulse_t SpindleLaser::testPulse = 50;                   // (ms) Test fire pulse default duration
+  uint8_t SpindleLaser::last_block_power; // = 0                      // Track power changes for dynamic inline power
+  feedRate_t SpindleLaser::feedrate_mm_m = 1500,
+             SpindleLaser::last_feedrate_mm_m; // = 0                 // (mm/min) Track feedrate changes for dynamic power
 #endif
-bool SpindleLaser::isReady;                                           // Ready to apply power setting from the UI to OCR
-cutter_power_t SpindleLaser::menuPower,                               // Power set via LCD menu in PWM, PERCENT, or RPM
-               SpindleLaser::unitPower;                               // LCD status power in PWM, PERCENT, or RPM
 
-#if ENABLED(MARLIN_DEV_MODE)
-  cutter_frequency_t SpindleLaser::frequency;                         // PWM frequency setting; range: 2K - 50K
-#endif
+bool SpindleLaser::isReadyForUI = false;                              // Ready to apply power setting from the UI to OCR
+CutterMode SpindleLaser::cutter_mode = CUTTER_MODE_STANDARD;          // Default is standard mode
+
+constexpr cutter_cpower_t SpindleLaser::power_floor;
+cutter_power_t SpindleLaser::menuPower = 0,                           // Power value via LCD menu in PWM, PERCENT, or RPM based on configured format set by CUTTER_POWER_UNIT.
+               SpindleLaser::unitPower = 0;                           // Unit power is in PWM, PERCENT, or RPM based on CUTTER_POWER_UNIT.
+
+cutter_frequency_t SpindleLaser::frequency;                           // PWM frequency setting; range: 2K - 50K
+
 #define SPINDLE_LASER_PWM_OFF TERN(SPINDLE_LASER_PWM_INVERT, 255, 0)
 
 /**
@@ -65,14 +73,14 @@ void SpindleLaser::init() {
   #if ENABLED(SPINDLE_CHANGE_DIR)
     OUT_WRITE(SPINDLE_DIR_PIN, SPINDLE_INVERT_DIR);                   // Init rotation to clockwise (M3)
   #endif
+  #if ENABLED(HAL_CAN_SET_PWM_FREQ) && SPINDLE_LASER_FREQUENCY
+    frequency = SPINDLE_LASER_FREQUENCY;
+    hal.set_pwm_frequency(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_FREQUENCY);
+  #endif
   #if ENABLED(SPINDLE_LASER_USE_PWM)
     SET_PWM(SPINDLE_LASER_PWM_PIN);
     hal.set_pwm_duty(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_PWM_OFF); // Set to lowest speed
   #endif
-  #if ENABLED(HAL_CAN_SET_PWM_FREQ) && SPINDLE_LASER_FREQUENCY
-    hal.set_pwm_frequency(pin_t(SPINDLE_LASER_PWM_PIN), SPINDLE_LASER_FREQUENCY);
-    TERN_(MARLIN_DEV_MODE, frequency = SPINDLE_LASER_FREQUENCY);
-  #endif
   #if ENABLED(AIR_EVACUATION)
     OUT_WRITE(AIR_EVACUATION_PIN, !AIR_EVACUATION_ACTIVE);            // Init Vacuum/Blower OFF
   #endif
@@ -90,7 +98,7 @@ void SpindleLaser::init() {
    */
   void SpindleLaser::_set_ocr(const uint8_t ocr) {
     #if ENABLED(HAL_CAN_SET_PWM_FREQ) && SPINDLE_LASER_FREQUENCY
-      hal.set_pwm_frequency(pin_t(SPINDLE_LASER_PWM_PIN), TERN(MARLIN_DEV_MODE, frequency, SPINDLE_LASER_FREQUENCY));
+      hal.set_pwm_frequency(pin_t(SPINDLE_LASER_PWM_PIN), frequency);
     #endif
     hal.set_pwm_duty(pin_t(SPINDLE_LASER_PWM_PIN), ocr ^ SPINDLE_LASER_PWM_OFF);
   }
@@ -107,35 +115,41 @@ void SpindleLaser::init() {
 #endif // SPINDLE_LASER_USE_PWM
 
 /**
- * Apply power for laser/spindle
+ * Apply power for Laser or Spindle
  *
  * Apply cutter power value for PWM, Servo, and on/off pin.
  *
- * @param opwr Power value. Range 0 to MAX. When 0 disable spindle/laser.
+ * @param opwr Power value. Range 0 to MAX.
  */
 void SpindleLaser::apply_power(const uint8_t opwr) {
-  if (opwr == last_power_applied) return;
-  last_power_applied = opwr;
-  power = opwr;
-  #if ENABLED(SPINDLE_LASER_USE_PWM)
-    if (cutter.unitPower == 0 && CUTTER_UNIT_IS(RPM)) {
-      ocr_off();
-      isReady = false;
-    }
-    else if (ENABLED(CUTTER_POWER_RELATIVE) || enabled()) {
-      set_ocr(power);
-      isReady = true;
-    }
-    else {
-      ocr_off();
-      isReady = false;
-    }
-  #elif ENABLED(SPINDLE_SERVO)
-    servo[SPINDLE_SERVO_NR].move(power);
-  #else
-    WRITE(SPINDLE_LASER_ENA_PIN, enabled() ? SPINDLE_LASER_ACTIVE_STATE : !SPINDLE_LASER_ACTIVE_STATE);
-    isReady = true;
-  #endif
+  if (enabled() || opwr == 0) {                                   // 0 check allows us to disable where no ENA pin exists
+    // Test and set the last power used to improve performance
+    if (opwr == last_power_applied) return;
+    last_power_applied = opwr;
+    // Handle PWM driven or just simple on/off
+    #if ENABLED(SPINDLE_LASER_USE_PWM)
+      if (CUTTER_UNIT_IS(RPM) && unitPower == 0)
+        ocr_off();
+      else if (ENABLED(CUTTER_POWER_RELATIVE) || enabled() || opwr == 0) {
+        set_ocr(opwr);
+        isReadyForUI = true;
+      }
+      else
+        ocr_off();
+    #elif ENABLED(SPINDLE_SERVO)
+      MOVE_SERVO(SPINDLE_SERVO_NR, power);
+    #else
+      WRITE(SPINDLE_LASER_ENA_PIN, enabled() ? SPINDLE_LASER_ACTIVE_STATE : !SPINDLE_LASER_ACTIVE_STATE);
+      isReadyForUI = true;
+    #endif
+  }
+  else {
+    #if PIN_EXISTS(SPINDLE_LASER_ENA)
+      WRITE(SPINDLE_LASER_ENA_PIN, !SPINDLE_LASER_ACTIVE_STATE);
+    #endif
+    isReadyForUI = false; // Only used for UI display updates.
+    TERN_(SPINDLE_LASER_USE_PWM, ocr_off());
+  }
 }
 
 #if ENABLED(SPINDLE_CHANGE_DIR)