TMC SPI Endstops and Improved Sensorless Homing (#14044)

Marlin/Configuration_adv.h

@@ -1851,17 +1851,25 @@
   #define E5_HYBRID_THRESHOLD     30
 
   /**
+   * Use StallGuard2 to home / probe X, Y, Z.
+   *
    * TMC2130, TMC2160, TMC2209, TMC2660, TMC5130, and TMC5160 only
-   * Use StallGuard2 to sense an obstacle and trigger an endstop.
    * Connect the stepper driver's DIAG1 pin to the X/Y endstop pin.
    * X, Y, and Z homing will always be done in spreadCycle mode.
    *
-   * X/Y/Z_STALL_SENSITIVITY is used for tuning the trigger sensitivity.
+   * X/Y/Z_STALL_SENSITIVITY is used to tune the trigger sensitivity.
-   * Higher values make the system LESS sensitive.
+   * Use M914 X Y Z to live-adjust the sensitivity.
-   * Lower value make the system MORE sensitive.
+   *  Higher: LESS sensitive. (Too high => failure to trigger)
-   * Too low values can lead to false positives, while too high values will collide the axis without triggering.
+   *   Lower: MORE sensitive. (Too low  => false positives)
-   * It is advised to set X/Y/Z_HOME_BUMP_MM to 0.
+   *
-   * M914 X/Y/Z to live tune the setting
+   * It is recommended to set [XYZ]_HOME_BUMP_MM to 0.
+   *
+   * SPI_ENDSTOPS  *** Beta feature! *** TMC2130 Only ***
+   * Poll the driver through SPI to determine load when homing.
+   * Removes the need for a wire from DIAG1 to an endstop pin.
+   *
+   * IMPROVE_HOMING_RELIABILITY tunes acceleration and jerk when
+   * homing and adds a guard period for endstop triggering.
    */
   //#define SENSORLESS_HOMING // StallGuard capable drivers only
 
@@ -1878,6 +1886,8 @@
     #define X_STALL_SENSITIVITY  8
     #define Y_STALL_SENSITIVITY  8
     //#define Z_STALL_SENSITIVITY  8
+    //#define SPI_ENDSTOPS              // TMC2130 only
+    //#define IMPROVE_HOMING_RELIABILITY
   #endif
 
   /**

Marlin/src/Marlin.cpp

@@ -659,6 +659,13 @@ void idle(
     bool no_stepper_sleep/*=false*/
   #endif
 ) {
+
+  #if ENABLED(SPI_ENDSTOPS)
+    if (endstops.tmc_spi_homing.any && ELAPSED(millis(), sg_guard_period))
+      for (uint8_t i = 4; i--;) // Read SGT 4 times per idle loop
+        if (endstops.tmc_spi_homing_check()) break;
+  #endif
+
   #if ENABLED(MAX7219_DEBUG)
     max7219.idle_tasks();
   #endif

Marlin/src/feature/tmc_util.h

@@ -140,6 +140,9 @@ class TMCMarlin : public TMC, public TMCStorage<AXIS_LETTER, DRIVER_ID> {
           this->stored.homing_thrs = sgt_val;
         #endif
       }
+      #if ENABLED(SPI_ENDSTOPS)
+        bool test_stall_status();
+      #endif
     #endif
 
     #if HAS_LCD_MENU
@@ -355,9 +358,22 @@ void test_tmc_connection(const bool test_x, const bool test_y, const bool test_z
  * Defined here because of limitations with templates and headers.
  */
 #if USE_SENSORLESS
+
   // Track enabled status of stealthChop and only re-enable where applicable
   struct sensorless_t { bool x, y, z, x2, y2, z2, z3; };
 
+  #if ENABLED(IMPROVE_HOMING_RELIABILITY)
+    extern millis_t sg_guard_period;
+    constexpr uint16_t default_sg_guard_duration = 400;
+
+    struct slow_homing_t {
+      struct { uint32_t x, y; } acceleration;
+      #if HAS_CLASSIC_JERK
+        struct { float x, y; } jerk;
+      #endif
+    };
+  #endif
+
   bool tmc_enable_stallguard(TMC2130Stepper &st);
   void tmc_disable_stallguard(TMC2130Stepper &st, const bool restore_stealth);
 
@@ -366,7 +382,42 @@ void test_tmc_connection(const bool test_x, const bool test_y, const bool test_z
 
   bool tmc_enable_stallguard(TMC2660Stepper);
   void tmc_disable_stallguard(TMC2660Stepper, const bool);
-#endif
+
+  #if ENABLED(SPI_ENDSTOPS)
+
+    template<class TMC, char AXIS_LETTER, char DRIVER_ID, AxisEnum AXIS_ID>
+    bool TMCMarlin<TMC, AXIS_LETTER, DRIVER_ID, AXIS_ID>::test_stall_status() {
+      uint16_t sg_result = 0;
+
+      this->switchCSpin(LOW);
+
+      if (this->TMC_SW_SPI != nullptr) {
+        this->TMC_SW_SPI->transfer(TMC2130_n::DRV_STATUS_t::address);
+        this->TMC_SW_SPI->transfer16(0);
+        // We only care about the last 10 bits
+        sg_result = this->TMC_SW_SPI->transfer(0);
+        sg_result <<= 8;
+        sg_result |= this->TMC_SW_SPI->transfer(0);
+      }
+      else {
+        SPI.beginTransaction(SPISettings(16000000/8, MSBFIRST, SPI_MODE3));
+        // Read DRV_STATUS
+        SPI.transfer(TMC2130_n::DRV_STATUS_t::address);
+        SPI.transfer16(0);
+        // We only care about the last 10 bits
+        sg_result = SPI.transfer(0);
+        sg_result <<= 8;
+        sg_result |= SPI.transfer(0);
+        SPI.endTransaction();
+      }
+      this->switchCSpin(HIGH);
+
+      return (sg_result & 0x3FF) == 0;
+    }
+
+  #endif // SPI_ENDSTOPS
+
+#endif // USE_SENSORLESS
 
 #if TMC_HAS_SPI
   void tmc_init_cs_pins();

Marlin/src/gcode/calibrate/G28.cpp

@@ -78,15 +78,19 @@
                 fr_mm_s = _MIN(homing_feedrate(X_AXIS), homing_feedrate(Y_AXIS)) * SQRT(sq(mlratio) + 1.0);
 
     #if ENABLED(SENSORLESS_HOMING)
-      sensorless_t stealth_states { false };
+      sensorless_t stealth_states {
-      stealth_states.x = tmc_enable_stallguard(stepperX);
+          tmc_enable_stallguard(stepperX)
-      stealth_states.y = tmc_enable_stallguard(stepperY);
+        , tmc_enable_stallguard(stepperY)
+        , false
+        , false
           #if AXIS_HAS_STALLGUARD(X2)
-        stealth_states.x2 = tmc_enable_stallguard(stepperX2);
+            || tmc_enable_stallguard(stepperX2)
           #endif
+        , false
           #if AXIS_HAS_STALLGUARD(Y2)
-        stealth_states.y2 = tmc_enable_stallguard(stepperY2);
+            || tmc_enable_stallguard(stepperY2)
           #endif
+      };
     #endif
 
     do_blocking_move_to_xy(1.5 * mlx * x_axis_home_dir, 1.5 * mly * home_dir(Y_AXIS), fr_mm_s);
@@ -229,6 +233,22 @@ void GcodeSuite::G28(const bool always_home_all) {
     workspace_plane = PLANE_XY;
   #endif
 
+  #if ENABLED(IMPROVE_HOMING_RELIABILITY)
+    slow_homing_t slow_homing { 0 };
+    slow_homing.acceleration.x = planner.settings.max_acceleration_mm_per_s2[X_AXIS];
+    slow_homing.acceleration.y = planner.settings.max_acceleration_mm_per_s2[Y_AXIS];
+    planner.settings.max_acceleration_mm_per_s2[X_AXIS] = 100;
+    planner.settings.max_acceleration_mm_per_s2[Y_AXIS] = 100;
+    #if HAS_CLASSIC_JERK
+      slow_homing.jerk.x = planner.max_jerk[X_AXIS];
+      slow_homing.jerk.y = planner.max_jerk[Y_AXIS];
+      planner.max_jerk[X_AXIS] = 0;
+      planner.max_jerk[Y_AXIS] = 0;
+    #endif
+
+    planner.reset_acceleration_rates();
+  #endif
+
   // Always home with tool 0 active
   #if HOTENDS > 1
     #if DISABLED(DELTA) || ENABLED(DELTA_HOME_TO_SAFE_ZONE)
@@ -393,6 +413,11 @@ void GcodeSuite::G28(const bool always_home_all) {
 
   endstops.not_homing();
 
+  // Clear endstop state for polled stallGuard endstops
+  #if ENABLED(SPI_ENDSTOPS)
+    endstops.clear_endstop_state();
+  #endif
+
   #if BOTH(DELTA, DELTA_HOME_TO_SAFE_ZONE)
     // move to a height where we can use the full xy-area
     do_blocking_move_to_z(delta_clip_start_height);
@@ -414,6 +439,17 @@ void GcodeSuite::G28(const bool always_home_all) {
     tool_change(old_tool_index, NO_FETCH);
   #endif
 
+  #if ENABLED(IMPROVE_HOMING_RELIABILITY)
+    planner.settings.max_acceleration_mm_per_s2[X_AXIS] = slow_homing.acceleration.x;
+    planner.settings.max_acceleration_mm_per_s2[Y_AXIS] = slow_homing.acceleration.y;
+    #if HAS_CLASSIC_JERK
+      planner.max_jerk[X_AXIS] = slow_homing.jerk.x;
+      planner.max_jerk[Y_AXIS] = slow_homing.jerk.y;
+    #endif
+
+    planner.reset_acceleration_rates();
+  #endif
+
   ui.refresh();
 
   report_current_position();

Marlin/src/inc/Conditionals_post.h

@@ -920,6 +920,11 @@
   #define X_SENSORLESS (AXIS_HAS_STALLGUARD(X) && defined(X_STALL_SENSITIVITY))
   #define Y_SENSORLESS (AXIS_HAS_STALLGUARD(Y) && defined(Y_STALL_SENSITIVITY))
   #define Z_SENSORLESS (AXIS_HAS_STALLGUARD(Z) && defined(Z_STALL_SENSITIVITY))
+  #if ENABLED(SPI_ENDSTOPS)
+    #define X_SPI_SENSORLESS X_SENSORLESS
+    #define Y_SPI_SENSORLESS Y_SENSORLESS
+    #define Z_SPI_SENSORLESS Z_SENSORLESS
+  #endif
 #endif
 
 // Endstops and bed probe

Marlin/src/module/delta.cpp

@@ -227,10 +227,11 @@ void home_delta() {
 
   // Disable stealthChop if used. Enable diag1 pin on driver.
   #if ENABLED(SENSORLESS_HOMING)
-    sensorless_t stealth_states { false };
+    sensorless_t stealth_states {
-    stealth_states.x = tmc_enable_stallguard(stepperX);
+      tmc_enable_stallguard(stepperX),
-    stealth_states.y = tmc_enable_stallguard(stepperY);
+      tmc_enable_stallguard(stepperY),
-    stealth_states.z = tmc_enable_stallguard(stepperZ);
+      tmc_enable_stallguard(stepperZ)
+    };
   #endif
 
   // Move all carriages together linearly until an endstop is hit.

Marlin/src/module/endstops.cpp

@@ -76,6 +76,13 @@ Endstops::esbits_t Endstops::live_state = 0;
   float Endstops::z3_endstop_adj;
 #endif
 
+#if ENABLED(SPI_ENDSTOPS)
+  Endstops::tmc_spi_homing_t Endstops::tmc_spi_homing; // = 0
+#endif
+#if ENABLED(IMPROVE_HOMING_RELIABILITY)
+  millis_t sg_guard_period; // = 0
+#endif
+
 /**
  * Class and Instance Methods
  */
@@ -699,7 +706,7 @@ void Endstops::update() {
   // Now, we must signal, after validation, if an endstop limit is pressed or not
   if (stepper.axis_is_moving(X_AXIS)) {
     if (stepper.motor_direction(X_AXIS_HEAD)) { // -direction
-      #if HAS_X_MIN
+      #if HAS_X_MIN || (X_SPI_SENSORLESS && X_HOME_DIR < 0)
         #if ENABLED(X_DUAL_ENDSTOPS)
           PROCESS_DUAL_ENDSTOP(X, X2, MIN);
         #else
@@ -708,7 +715,7 @@ void Endstops::update() {
       #endif
     }
     else { // +direction
-      #if HAS_X_MAX
+      #if HAS_X_MAX || (X_SPI_SENSORLESS && X_HOME_DIR > 0)
         #if ENABLED(X_DUAL_ENDSTOPS)
           PROCESS_DUAL_ENDSTOP(X, X2, MAX);
         #else
@@ -720,7 +727,7 @@ void Endstops::update() {
 
   if (stepper.axis_is_moving(Y_AXIS)) {
     if (stepper.motor_direction(Y_AXIS_HEAD)) { // -direction
-      #if HAS_Y_MIN
+      #if HAS_Y_MIN || (Y_SPI_SENSORLESS && Y_HOME_DIR < 0)
         #if ENABLED(Y_DUAL_ENDSTOPS)
           PROCESS_DUAL_ENDSTOP(Y, Y2, MIN);
         #else
@@ -729,7 +736,7 @@ void Endstops::update() {
       #endif
     }
     else { // +direction
-      #if HAS_Y_MAX
+      #if HAS_Y_MAX || (Y_SPI_SENSORLESS && Y_HOME_DIR > 0)
         #if ENABLED(Y_DUAL_ENDSTOPS)
           PROCESS_DUAL_ENDSTOP(Y, Y2, MAX);
         #else
@@ -741,7 +748,7 @@ void Endstops::update() {
 
   if (stepper.axis_is_moving(Z_AXIS)) {
     if (stepper.motor_direction(Z_AXIS_HEAD)) { // Z -direction. Gantry down, bed up.
-      #if HAS_Z_MIN
+      #if HAS_Z_MIN || (Z_SPI_SENSORLESS && Z_HOME_DIR < 0)
         #if ENABLED(Z_TRIPLE_ENDSTOPS)
           PROCESS_TRIPLE_ENDSTOP(Z, Z2, Z3, MIN);
         #elif ENABLED(Z_DUAL_ENDSTOPS)
@@ -763,7 +770,7 @@ void Endstops::update() {
       #endif
     }
     else { // Z +direction. Gantry up, bed down.
-      #if HAS_Z_MAX
+      #if HAS_Z_MAX || (Z_SPI_SENSORLESS && Z_HOME_DIR > 0)
         #if ENABLED(Z_TRIPLE_ENDSTOPS)
           PROCESS_TRIPLE_ENDSTOP(Z, Z2, Z3, MAX);
         #elif ENABLED(Z_DUAL_ENDSTOPS)
@@ -778,6 +785,49 @@ void Endstops::update() {
   }
 } // Endstops::update()
 
+#if ENABLED(SPI_ENDSTOPS)
+
+  #define X_STOP (X_HOME_DIR < 0 ? X_MIN : X_MAX)
+  #define Y_STOP (Y_HOME_DIR < 0 ? Y_MIN : Y_MAX)
+  #define Z_STOP (Z_HOME_DIR < 0 ? Z_MIN : Z_MAX)
+
+  bool Endstops::tmc_spi_homing_check() {
+    bool hit = false;
+    #if X_SPI_SENSORLESS
+      if (tmc_spi_homing.x && stepperX.test_stall_status()) {
+        SBI(live_state, X_STOP);
+        hit = true;
+      }
+    #endif
+    #if Y_SPI_SENSORLESS
+      if (tmc_spi_homing.y && stepperY.test_stall_status()) {
+        SBI(live_state, Y_STOP);
+        hit = true;
+      }
+    #endif
+    #if Z_SPI_SENSORLESS
+      if (tmc_spi_homing.z && stepperZ.test_stall_status()) {
+        SBI(live_state, Z_STOP);
+        hit = true;
+      }
+    #endif
+    return hit;
+  }
+
+  void Endstops::clear_endstop_state() {
+    #if X_SPI_SENSORLESS
+      CBI(live_state, X_STOP);
+    #endif
+    #if Y_SPI_SENSORLESS
+      CBI(live_state, Y_STOP);
+    #endif
+    #if Z_SPI_SENSORLESS
+      CBI(live_state, Z_STOP);
+    #endif
+  }
+
+#endif // SPI_ENDSTOPS
+
 #if ENABLED(PINS_DEBUGGING)
 
   bool Endstops::monitor_flag = false;

Marlin/src/module/endstops.h

@@ -161,6 +161,18 @@ class Endstops {
       static void monitor();
       static void run_monitor();
     #endif
+
+    #if ENABLED(SPI_ENDSTOPS)
+      typedef struct {
+        union {
+          bool any;
+          struct { bool x:1, y:1, z:1; };
+        };
+      } tmc_spi_homing_t;
+      static tmc_spi_homing_t tmc_spi_homing;
+      static void clear_endstop_state();
+      static bool tmc_spi_homing_check();
+    #endif
 };
 
 extern Endstops endstops;

Marlin/src/module/motion.cpp

@@ -1121,6 +1121,26 @@ float get_homing_bump_feedrate(const AxisEnum axis) {
           break;
       #endif
     }
+
+    #if ENABLED(SPI_ENDSTOPS)
+      switch (axis) {
+        #if X_SPI_SENSORLESS
+          case X_AXIS: endstops.tmc_spi_homing.x = true; break;
+        #endif
+        #if Y_SPI_SENSORLESS
+          case Y_AXIS: endstops.tmc_spi_homing.y = true; break;
+        #endif
+        #if Z_SPI_SENSORLESS
+          case Z_AXIS: endstops.tmc_spi_homing.z = true; break;
+        #endif
+        default: break;
+      }
+    #endif
+
+    #if ENABLED(IMPROVE_HOMING_RELIABILITY)
+      sg_guard_period = millis() + default_sg_guard_duration;
+    #endif
+
     return stealth_states;
   }
 
@@ -1170,6 +1190,21 @@ float get_homing_bump_feedrate(const AxisEnum axis) {
           break;
       #endif
     }
+
+    #if ENABLED(SPI_ENDSTOPS)
+      switch (axis) {
+        #if X_SPI_SENSORLESS
+          case X_AXIS: endstops.tmc_spi_homing.x = false; break;
+        #endif
+        #if Y_SPI_SENSORLESS
+          case Y_AXIS: endstops.tmc_spi_homing.y = false; break;
+        #endif
+        #if Z_SPI_SENSORLESS
+          case Z_AXIS: endstops.tmc_spi_homing.z = false; break;
+        #endif
+        default: break;
+      }
+    #endif
   }
 
 #endif // SENSORLESS_HOMING
@@ -1383,9 +1418,24 @@ void homeaxis(const AxisEnum axis) {
     // Only Z homing (with probe) is permitted
     if (axis != Z_AXIS) { BUZZ(100, 880); return; }
   #else
-    #define CAN_HOME(A) \
+    #define _CAN_HOME(A) \
       (axis == _AXIS(A) && ((A##_MIN_PIN > -1 && A##_HOME_DIR < 0) || (A##_MAX_PIN > -1 && A##_HOME_DIR > 0)))
-    if (!CAN_HOME(X) && !CAN_HOME(Y) && !CAN_HOME(Z)) return;
+    #if X_SPI_SENSORLESS
+      #define CAN_HOME_X true
+    #else
+      #define CAN_HOME_X _CAN_HOME(X)
+    #endif
+    #if Y_SPI_SENSORLESS
+      #define CAN_HOME_Y true
+    #else
+      #define CAN_HOME_Y _CAN_HOME(Y)
+    #endif
+    #if Z_SPI_SENSORLESS
+      #define CAN_HOME_Z true
+    #else
+      #define CAN_HOME_Z _CAN_HOME(Z)
+    #endif
+    if (!CAN_HOME_X && !CAN_HOME_Y && !CAN_HOME_Z) return;
   #endif
 
   if (DEBUGGING(LEVELING)) DEBUG_ECHOLNPAIR(">>> homeaxis(", axis_codes[axis], ")");