⚡️ PWM for ESP32 I2S expander (#24193)

Marlin/Configuration_adv.h

@@ -3472,7 +3472,10 @@
   #if ENABLED(SPINDLE_LASER_USE_PWM)
     #define SPINDLE_LASER_PWM_INVERT    false  // Set to "true" if the speed/power goes up when you want it to go slower
     #define SPINDLE_LASER_FREQUENCY     2500   // (Hz) Spindle/laser frequency (only on supported HALs: AVR, ESP32, and LPC)
-  #endif
+                                               // 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
 
   //#define AIR_EVACUATION                     // Cutter Vacuum / Laser Blower motor control with G-codes M10-M11
   #if ENABLED(AIR_EVACUATION)

Marlin/Makefile

@@ -109,7 +109,7 @@ LIQUID_TWI2        ?= 0
 # This defines if Wire is needed
 WIRE               ?= 0
 
-# This defines if Tone is needed (i.e SPEAKER is defined in Configuration.h)
+# This defines if Tone is needed (i.e., SPEAKER is defined in Configuration.h)
 # Disabling this (and SPEAKER) saves approximately 350 bytes of memory.
 TONE               ?= 1
 

Marlin/src/HAL/ESP32/HAL.cpp

@@ -65,6 +65,7 @@ portMUX_TYPE MarlinHAL::spinlock = portMUX_INITIALIZER_UNLOCKED;
 // ------------------------
 
 uint16_t MarlinHAL::adc_result;
+pwm_pin_t MarlinHAL::pwm_pin_data[MAX_EXPANDER_BITS];
 
 // ------------------------
 // Private Variables
@@ -330,21 +331,46 @@ int8_t get_pwm_channel(const pin_t pin, const uint32_t freq, const uint16_t res)
 }
 
 void MarlinHAL::set_pwm_duty(const pin_t pin, const uint16_t v, const uint16_t v_size/*=_BV(PWM_RESOLUTION)-1*/, const bool invert/*=false*/) {
-  const int8_t cid = get_pwm_channel(pin, PWM_FREQUENCY, PWM_RESOLUTION);
+  #if ENABLED(I2S_STEPPER_STREAM)
-  if (cid >= 0) {
+    if (pin > 127) {
-    uint32_t duty = map(invert ? v_size - v : v, 0, v_size, 0, _BV(PWM_RESOLUTION)-1);
+      const uint8_t pinlo = pin & 0x7F;
-    ledcWrite(cid, duty);
+      pwm_pin_t &pindata = pwm_pin_data[pinlo];
-  }
+      const uint32_t duty = map(invert ? v_size - v : v, 0, v_size, 0, pindata.pwm_cycle_ticks);
+      if (duty == 0 || duty == pindata.pwm_cycle_ticks) { // max or min (i.e., on/off)
+        pindata.pwm_duty_ticks = 0;  // turn off PWM for this pin
+        duty ? SBI32(i2s_port_data, pinlo) : CBI32(i2s_port_data, pinlo); // set pin level
+      }
+      else
+        pindata.pwm_duty_ticks = duty; // PWM duty count = # of 4µs ticks per full PWM cycle
+    }
+    else
+  #endif
+    {
+      const int8_t cid = get_pwm_channel(pin, PWM_FREQUENCY, PWM_RESOLUTION);
+      if (cid >= 0) {
+        const uint32_t duty = map(invert ? v_size - v : v, 0, v_size, 0, _BV(PWM_RESOLUTION)-1);
+        ledcWrite(cid, duty);
+      }
+    }
 }
 
 int8_t MarlinHAL::set_pwm_frequency(const pin_t pin, const uint32_t f_desired) {
-  const int8_t cid = channel_for_pin(pin);
+  #if ENABLED(I2S_STEPPER_STREAM)
-  if (cid >= 0) {
+    if (pin > 127) {
-    if (f_desired == ledcReadFreq(cid)) return cid; // no freq change
+      pwm_pin_data[pin & 0x7F].pwm_cycle_ticks = 1000000UL / f_desired / 4; // # of 4µs ticks per full PWM cycle
-    ledcDetachPin(chan_pin[cid]);
+      return 0;
-    chan_pin[cid] = 0;              // remove old freq channel
+    }
-  }
+    else
-  return get_pwm_channel(pin, f_desired, PWM_RESOLUTION); // try for new one
+  #endif
+    {
+      const int8_t cid = channel_for_pin(pin);
+      if (cid >= 0) {
+        if (f_desired == ledcReadFreq(cid)) return cid; // no freq change
+        ledcDetachPin(chan_pin[cid]);
+        chan_pin[cid] = 0;              // remove old freq channel
+      }
+      return get_pwm_channel(pin, f_desired, PWM_RESOLUTION); // try for new one
+    }
 }
 
 // use hardware PWM if avail, if not then ISR

Marlin/src/HAL/ESP32/HAL.h

@@ -68,6 +68,9 @@
 #define PWM_RESOLUTION   10u   // Default PWM bit resolution
 #define CHANNEL_MAX_NUM  15u   // max PWM channel # to allocate (7 to only use low speed, 15 to use low & high)
 #define MAX_PWM_IOPIN    33u   // hardware pwm pins < 34
+#ifndef MAX_EXPANDER_BITS
+  #define MAX_EXPANDER_BITS 32 // I2S expander bit width (max 32)
+#endif
 
 // ------------------------
 // Types
@@ -76,6 +79,12 @@
 typedef double isr_float_t;   // FPU ops are used for single-precision, so use double for ISRs.
 typedef int16_t pin_t;
 
+typedef struct pwm_pin {
+  uint32_t pwm_cycle_ticks = 1000000UL / (PWM_FREQUENCY) / 4; // # ticks per pwm cycle
+  uint32_t pwm_tick_count = 0;  // current tick count
+  uint32_t pwm_duty_ticks = 0;  // # of ticks for current duty cycle
+} pwm_pin_t;
+
 class Servo;
 typedef Servo hal_servo_t;
 
@@ -197,6 +206,8 @@ public:
   // Free SRAM
   static int freeMemory();
 
+  static pwm_pin_t pwm_pin_data[MAX_EXPANDER_BITS];
+
   //
   // ADC Methods
   //

Marlin/src/HAL/ESP32/i2s.cpp

@@ -337,6 +337,26 @@ uint8_t i2s_state(uint8_t pin) {
 }
 
 void i2s_push_sample() {
+  // Every 4µs (when space in DMA buffer) toggle each expander PWM output using
+  // the current duty cycle/frequency so they sync with any steps (once
+  // through the DMA/FIFO buffers).  PWM signal inversion handled by other functions
+  LOOP_L_N(p, MAX_EXPANDER_BITS) {
+    if (hal.pwm_pin_data[p].pwm_duty_ticks > 0) { // pin has active pwm?
+      if (hal.pwm_pin_data[p].pwm_tick_count == 0) {
+        if (TEST32(i2s_port_data, p)) {  // hi->lo
+          CBI32(i2s_port_data, p);
+          hal.pwm_pin_data[p].pwm_tick_count = hal.pwm_pin_data[p].pwm_cycle_ticks - hal.pwm_pin_data[p].pwm_duty_ticks;
+        }
+        else { // lo->hi
+          SBI32(i2s_port_data, p);
+          hal.pwm_pin_data[p].pwm_tick_count = hal.pwm_pin_data[p].pwm_duty_ticks;
+        }
+      }
+      else
+        hal.pwm_pin_data[p].pwm_tick_count--;
+    }
+  }
+
   dma.current[dma.rw_pos++] = i2s_port_data;
 }
 

Marlin/src/HAL/ESP32/inc/Conditionals_adv.h

@@ -20,3 +20,10 @@
  *
  */
 #pragma once
+
+//
+// Board-specific options need to be defined before HAL.h
+//
+#if MB(MKS_TINYBEE)
+  #define MAX_EXPANDER_BITS 24  // TinyBee has 3 x HC595
+#endif

Marlin/src/HAL/ESP32/inc/SanityCheck.h

@@ -48,3 +48,7 @@
 #if USING_PULLDOWNS
   #error "PULLDOWN pin mode is not available on ESP32 boards."
 #endif
+
+#if BOTH(I2S_STEPPER_STREAM, LIN_ADVANCE)
+  #error "I2S stream is currently incompatible with LIN_ADVANCE."
+#endif

Marlin/src/module/stepper.cpp

@@ -1863,9 +1863,7 @@ void Stepper::pulse_phase_isr() {
       #endif
     #endif
 
-    #if ENABLED(I2S_STEPPER_STREAM)
+    TERN_(I2S_STEPPER_STREAM, i2s_push_sample());
-      i2s_push_sample();
-    #endif
 
     // TODO: need to deal with MINIMUM_STEPPER_PULSE over i2s
     #if ISR_MULTI_STEPS

Marlin/src/pins/esp32/pins_E4D.h

@@ -40,19 +40,14 @@
 #define BOARD_WEBSITE_URL     "github.com/Exilaus/E4d@box"
 #define DEFAULT_MACHINE_NAME  BOARD_INFO_NAME
 
-//
-// Disable I2S stepper stream
-//
-#undef I2S_STEPPER_STREAM
-
 //
 // Redefine I2S for ESP32
 //
 #undef I2S_WS
-#define I2S_WS                                23
 #undef I2S_BCK
-#define I2S_BCK                               22
 #undef I2S_DATA
+#define I2S_WS                                23
+#define I2S_BCK                               22
 #define I2S_DATA                              21
 
 //

Marlin/src/pins/esp32/pins_ENWI_ESPNP.h

@@ -35,9 +35,11 @@
 // I2S (steppers & other output-only pins)
 //
 #define I2S_STEPPER_STREAM
-#define I2S_WS                                17
+#if ENABLED(I2S_STEPPER_STREAM)
-#define I2S_BCK                               22
+  #define I2S_WS                              17
-#define I2S_DATA                              21
+  #define I2S_BCK                             22
+  #define I2S_DATA                            21
+#endif
 
 //
 // Servos

Marlin/src/pins/esp32/pins_ESP32.h

@@ -33,9 +33,11 @@
 // I2S (steppers & other output-only pins)
 //
 #define I2S_STEPPER_STREAM
-#define I2S_WS                                25
+#if ENABLED(I2S_STEPPER_STREAM)
-#define I2S_BCK                               26
+  #define I2S_WS                              25
-#define I2S_DATA                              27
+  #define I2S_BCK                             26
+  #define I2S_DATA                            27
+#endif
 
 //
 // Limit Switches

Marlin/src/pins/esp32/pins_ESPA_common.h

@@ -32,14 +32,6 @@
   #define DEFAULT_MACHINE_NAME  BOARD_INFO_NAME
 #endif
 
-//
-// Disable I2S stepper stream, by default
-//
-#undef I2S_STEPPER_STREAM
-#undef I2S_WS
-#undef I2S_BCK
-#undef I2S_DATA
-
 //
 // Limit Switches
 //

Marlin/src/pins/esp32/pins_MKS_TINYBEE.h

@@ -40,6 +40,8 @@
 #define BOARD_WEBSITE_URL    "https://github.com/makerbase-mks"
 #define DEFAULT_MACHINE_NAME BOARD_INFO_NAME
 
+// MAX_EXPANDER_BITS is defined for MKS TinyBee in HAL/ESP32/inc/Conditionals_adv.h
+
 //
 // Servos
 //
@@ -61,9 +63,6 @@
   #define I2S_WS                              26
   #define I2S_BCK                             25
   #define I2S_DATA                            27
-  #if ENABLED(LIN_ADVANCE)
-    #error "I2S stream is currently incompatible with LIN_ADVANCE."
-  #endif
 #endif
 
 //

Marlin/src/pins/esp32/pins_MRR_ESPE.h

@@ -52,11 +52,10 @@
 // Enable I2S stepper stream
 //
 #define I2S_STEPPER_STREAM
-#define I2S_WS                                26
+#if ENABLED(I2S_STEPPER_STREAM)
-#define I2S_BCK                               25
+  #define I2S_WS                              26
-#define I2S_DATA                              27
+  #define I2S_BCK                             25
-#if ENABLED(LIN_ADVANCE)
+  #define I2S_DATA                            27
-  #error "I2S stream is currently incompatible with LIN_ADVANCE."
 #endif
 
 //