🚸 Fix, Improve Power-Loss Recovery (#22828)

Co-authored-by: Scott Lahteine <github@thinkyhead.com>

Marlin/src/feature/powerloss.cpp

@@ -54,6 +54,10 @@ uint32_t PrintJobRecovery::cmd_sdpos, // = 0
 #include "../module/temperature.h"
 #include "../core/serial.h"
 
+#if HOMING_Z_WITH_PROBE
+  #include "../module/probe.h"
+#endif
+
 #if ENABLED(FWRETRACT)
   #include "fwretract.h"
 #endif
@@ -178,7 +182,8 @@ void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=POW
     info.valid_foot = info.valid_head;
 
     // Machine state
-    info.current_position = current_position;
+    // info.sdpos and info.current_position are pre-filled from the Stepper ISR
+
     info.feedrate = uint16_t(MMS_TO_MMM(feedrate_mm_s));
     info.zraise = zraise;
     info.flag.raised = raised;                      // Was Z raised before power-off?
@@ -265,6 +270,10 @@ void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=POW
 
   #endif
 
+#endif // POWER_LOSS_PIN
+
+#if PIN_EXISTS(POWER_LOSS) || ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+
   /**
    * An outage was detected by a sensor pin.
    *  - If not SD printing, let the machine turn off on its own with no "KILL" screen
@@ -273,7 +282,7 @@ void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=POW
    *  - If backup power is available Retract E and Raise Z
    *  - Go to the KILL screen
    */
-  void PrintJobRecovery::_outage() {
+  void PrintJobRecovery::_outage(TERN_(DEBUG_POWER_LOSS_RECOVERY, const bool simulated/*=false*/)) {
     #if ENABLED(BACKUP_POWER_SUPPLY)
       static bool lock = false;
       if (lock) return; // No re-entrance from idle() during retract_and_lift()
@@ -301,10 +310,16 @@ void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=POW
       retract_and_lift(zraise);
     #endif
 
-    kill(GET_TEXT_F(MSG_OUTAGE_RECOVERY));
+    if (TERN0(DEBUG_POWER_LOSS_RECOVERY, simulated)) {
+      card.fileHasFinished();
+      current_position.reset();
+      sync_plan_position();
+    }
+    else
+      kill(GET_TEXT_F(MSG_OUTAGE_RECOVERY));
   }
 
-#endif
+#endif // POWER_LOSS_PIN || DEBUG_POWER_LOSS_RECOVERY
 
 /**
  * Save the recovery info the recovery file
@@ -390,14 +405,12 @@ void PrintJobRecovery::resume() {
 
     #if ENABLED(POWER_LOSS_RECOVER_ZHOME) && defined(POWER_LOSS_ZHOME_POS)
       #define HOMING_Z_DOWN 1
-    #else
-      #define HOME_XY_ONLY 1
     #endif
 
     float z_now = info.flag.raised ? z_raised : z_print;
 
-    // Reset E to 0 and set Z to the real position
+    #if !HOMING_Z_DOWN
-    #if HOME_XY_ONLY
+      // Set Z to the real position
       sprintf_P(cmd, PSTR("G92.9Z%s"), dtostrf(z_now, 1, 3, str_1));
       gcode.process_subcommands_now(cmd);
     #endif
@@ -409,15 +422,15 @@ void PrintJobRecovery::resume() {
       gcode.process_subcommands_now(cmd);
     }
 
-    // Home XY with no Z raise, and also home Z here if Z isn't homing down below.
+    // Home XY with no Z raise
-    gcode.process_subcommands_now(F("G28R0" TERN_(HOME_XY_ONLY, "XY"))); // No raise during G28
+    gcode.process_subcommands_now(F("G28R0XY")); // No raise during G28
 
   #endif
 
   #if HOMING_Z_DOWN
     // Move to a safe XY position and home Z while avoiding the print.
-    constexpr xy_pos_t p = POWER_LOSS_ZHOME_POS;
+    const xy_pos_t p = xy_pos_t(POWER_LOSS_ZHOME_POS) TERN_(HOMING_Z_WITH_PROBE, - probe.offset_xy);
-    sprintf_P(cmd, PSTR("G1X%sY%sF1000\nG28Z"), dtostrf(p.x, 1, 3, str_1), dtostrf(p.y, 1, 3, str_2));
+    sprintf_P(cmd, PSTR("G1X%sY%sF1000\nG28HZ"), dtostrf(p.x, 1, 3, str_1), dtostrf(p.y, 1, 3, str_2));
     gcode.process_subcommands_now(cmd);
   #endif
 
@@ -431,7 +444,7 @@ void PrintJobRecovery::resume() {
     sprintf_P(cmd, PSTR("M420S%cZ%s"), '0' + (char)info.flag.leveling, dtostrf(info.fade, 1, 1, str_1));
     gcode.process_subcommands_now(cmd);
 
-    #if HOME_XY_ONLY
+    #if !HOMING_Z_DOWN
       // The physical Z was adjusted at power-off so undo the M420S1 correction to Z with G92.9.
       sprintf_P(cmd, PSTR("G92.9Z%s"), dtostrf(z_now, 1, 1, str_1));
       gcode.process_subcommands_now(cmd);
@@ -513,12 +526,12 @@ void PrintJobRecovery::resume() {
 
   // Un-retract if there was a retract at outage
   #if ENABLED(BACKUP_POWER_SUPPLY) && POWER_LOSS_RETRACT_LEN > 0
-    gcode.process_subcommands_now(F("G1E" STRINGIFY(POWER_LOSS_RETRACT_LEN) "F3000"));
+    gcode.process_subcommands_now(F("G1F3000E" STRINGIFY(POWER_LOSS_RETRACT_LEN)));
   #endif
 
   // Additional purge on resume if configured
   #if POWER_LOSS_PURGE_LEN
-    sprintf_P(cmd, PSTR("G1 E%d F3000"), (POWER_LOSS_PURGE_LEN) + (POWER_LOSS_RETRACT_LEN));
+    sprintf_P(cmd, PSTR("G1F3000E%d"), (POWER_LOSS_PURGE_LEN) + (POWER_LOSS_RETRACT_LEN));
     gcode.process_subcommands_now(cmd);
   #endif
 

Marlin/src/feature/powerloss.h

@@ -216,9 +216,9 @@ class PrintJobRecovery {
       static void retract_and_lift(const_float_t zraise);
     #endif
 
-    #if PIN_EXISTS(POWER_LOSS)
+    #if PIN_EXISTS(POWER_LOSS) || ENABLED(DEBUG_POWER_LOSS_RECOVERY)
       friend class GcodeSuite;
-      static void _outage();
+      static void _outage(TERN_(DEBUG_POWER_LOSS_RECOVERY, const bool simulated=false));
     #endif
 };
 

Marlin/src/gcode/calibrate/G28.cpp

@@ -395,9 +395,10 @@ void GcodeSuite::G28() {
 
     TERN_(HOME_Z_FIRST, if (doZ) homeaxis(Z_AXIS));
 
-    const float z_homing_height = parser.seenval('R') ? parser.value_linear_units() : Z_HOMING_HEIGHT;
+    const bool seenR = parser.seenval('R');
+    const float z_homing_height = seenR ? parser.value_linear_units() : Z_HOMING_HEIGHT;
 
-    if (z_homing_height && (LINEAR_AXIS_GANG(doX, || doY, || TERN0(Z_SAFE_HOMING, doZ), || doI, || doJ, || doK))) {
+    if (z_homing_height && (seenR || LINEAR_AXIS_GANG(doX, || doY, || TERN0(Z_SAFE_HOMING, doZ), || doI, || doJ, || doK))) {
       // Raise Z before homing any other axes and z is not already high enough (never lower z)
       if (DEBUGGING(LEVELING)) DEBUG_ECHOLNPGM("Raise Z (before homing) by ", z_homing_height);
       do_z_clearance(z_homing_height);
@@ -451,7 +452,11 @@ void GcodeSuite::G28() {
           stepper.set_separate_multi_axis(false);
         #endif
 
-        TERN(Z_SAFE_HOMING, home_z_safely(), homeaxis(Z_AXIS));
+        #if ENABLED(Z_SAFE_HOMING)
+          if (TERN1(POWER_LOSS_RECOVERY, !parser.seen_test('H'))) home_z_safely(); else homeaxis(Z_AXIS);
+        #else
+          homeaxis(Z_AXIS);
+        #endif
         probe.move_z_after_homing();
       }
     #endif

Marlin/src/gcode/feature/powerloss/M413.cpp

@@ -48,9 +48,8 @@ void GcodeSuite::M413() {
     if (parser.seen_test('W')) recovery.save(true);
     if (parser.seen_test('P')) recovery.purge();
     if (parser.seen_test('D')) recovery.debug(F("M413"));
-    #if PIN_EXISTS(POWER_LOSS)
+    if (parser.seen_test('O')) recovery._outage(true);
-      if (parser.seen_test('O')) recovery._outage();
+    if (parser.seen_test('C')) recovery.check();
-    #endif
     if (parser.seen_test('E')) SERIAL_ECHOF(recovery.exists() ? F("PLR Exists\n") : F("No PLR\n"));
     if (parser.seen_test('V')) SERIAL_ECHOF(recovery.valid() ? F("Valid\n") : F("Invalid\n"));
   #endif

Marlin/src/inc/SanityCheck.h

@@ -3440,8 +3440,6 @@ static_assert(_PLUS_TEST(4), "HOMING_FEEDRATE_MM_M values must be positive.");
 #if ENABLED(POWER_LOSS_RECOVERY)
   #if ENABLED(BACKUP_POWER_SUPPLY) && !PIN_EXISTS(POWER_LOSS)
     #error "BACKUP_POWER_SUPPLY requires a POWER_LOSS_PIN."
-  #elif BOTH(POWER_LOSS_RECOVER_ZHOME, Z_SAFE_HOMING)
-    #error "POWER_LOSS_RECOVER_ZHOME cannot be used with Z_SAFE_HOMING."
   #elif BOTH(POWER_LOSS_PULLUP, POWER_LOSS_PULLDOWN)
     #error "You can't enable POWER_LOSS_PULLUP and POWER_LOSS_PULLDOWN at the same time."
   #elif ENABLED(POWER_LOSS_RECOVER_ZHOME) && Z_HOME_TO_MAX

Marlin/src/module/planner.cpp

@@ -2809,9 +2809,13 @@ bool Planner::_populate_block(block_t * const block, bool split_move,
 
   position = target;  // Update the position
 
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    block->sdpos = recovery.command_sdpos();
+    block->start_position = position_float.asLogical();
+  #endif
+
   TERN_(HAS_POSITION_FLOAT, position_float = target_float);
   TERN_(GRADIENT_MIX, mixer.gradient_control(target_float.z));
-  TERN_(POWER_LOSS_RECOVERY, block->sdpos = recovery.command_sdpos());
 
   return true;        // Movement was accepted
 

Marlin/src/module/planner.h

@@ -244,6 +244,7 @@ typedef struct block_t {
 
   #if ENABLED(POWER_LOSS_RECOVERY)
     uint32_t sdpos;
+    xyze_pos_t start_position;
   #endif
 
   #if ENABLED(LASER_POWER_INLINE)
@@ -252,7 +253,7 @@ typedef struct block_t {
 
 } block_t;
 
-#if ANY(LIN_ADVANCE, SCARA_FEEDRATE_SCALING, GRADIENT_MIX, LCD_SHOW_E_TOTAL)
+#if ANY(LIN_ADVANCE, SCARA_FEEDRATE_SCALING, GRADIENT_MIX, LCD_SHOW_E_TOTAL, POWER_LOSS_RECOVERY)
   #define HAS_POSITION_FLOAT 1
 #endif
 

Marlin/src/module/stepper.cpp

@@ -2151,7 +2151,10 @@ uint32_t Stepper::block_phase_isr() {
         cutter.apply_power(current_block->cutter_power);
       #endif
 
-      TERN_(POWER_LOSS_RECOVERY, recovery.info.sdpos = current_block->sdpos);
+      #if ENABLED(POWER_LOSS_RECOVERY)
+        recovery.info.sdpos = current_block->sdpos;
+        recovery.info.current_position = current_block->start_position;
+      #endif
 
       #if ENABLED(DIRECT_STEPPING)
         if (IS_PAGE(current_block)) {