Handle driver warnings and errors via the event handling system

Also removed delay to reporting driver OTPW when a fan has just been
turned on
Also bug fixes to event handling system

8 files changed, 104 insertions, 157 deletions

diff --git a/src/CAN/CanInterface.cpp b/src/CAN/CanInterface.cpp
index 9249dfc5..20c36877 100644
--- a/src/CAN/CanInterface.cpp
+++ b/src/CAN/CanInterface.cpp
@@ -350,8 +350,8 @@ void CanInterface::SendAnnounce(CanMessageBuffer *buf) noexcept
 void CanInterface::RaiseEvent(EventType type, uint16_t param, uint8_t device, const char *format, va_list vargs) noexcept
 {
 	CanMessageBuffer buf(nullptr);
-	auto msg = buf.SetupStatusMessage<CanMessageEvent>(CanInterface::GetCanAddress(), CanId::MasterAddress);
-	msg->eventType = EventType::heater_fault;
+	auto msg = buf.SetupStatusMessage<CanMessageEvent>(GetCanAddress(), GetCurrentMasterAddress());
+	msg->eventType = type.ToBaseType();;
 	msg->deviceNumber = device;
 	msg->eventParam = param;
 	msg->zero = 0;
diff --git a/src/CAN/CommandProcessor.cpp b/src/CAN/CommandProcessor.cpp
index 43d99b58..b74c4750 100644
--- a/src/CAN/CommandProcessor.cpp
+++ b/src/CAN/CommandProcessor.cpp
@@ -13,6 +13,7 @@
 #include <CanMessageBuffer.h>
 #include <Platform/RepRap.h>
 #include <Platform/Platform.h>
+#include <Platform/Event.h>
 #include <Heating/Heat.h>
 #include "ExpansionManager.h"
 # include <ClosedLoop/ClosedLoop.h>
@@ -655,6 +656,10 @@ void CommandProcessor::ProcessReceivedMessage(CanMessageBuffer *buf) noexcept
 				ClosedLoop::ProcessReceivedData(buf->id.Src(), buf->msg.closedLoopData, buf->dataLength);
 				break;
 
+			case CanMessageType::event:
+				Event::Add(buf->msg.event, buf->id.Src(), buf->dataLength);
+				break;
+
 #if SUPPORT_ACCELEROMETERS
 			case CanMessageType::accelerometerData:
 				Accelerometers::ProcessReceivedData(buf->id.Src(), buf->msg.accelerometerData, buf->dataLength);
diff --git a/src/Fans/LocalFan.cpp b/src/Fans/LocalFan.cpp
index 3acfce43..5e404258 100644
--- a/src/Fans/LocalFan.cpp
+++ b/src/Fans/LocalFan.cpp
@@ -70,9 +70,6 @@ void LocalFan::SetHardwarePwm(float pwmVal) noexcept
 void LocalFan::InternalRefresh(bool checkSensors) noexcept
 {
 	float reqVal;
-#if HAS_SMART_DRIVERS
-	DriverChannelsBitmap driverChannelsMonitored;
-#endif
 
 	if (sensorsMonitored.IsEmpty())
 	{
@@ -87,11 +84,7 @@ void LocalFan::InternalRefresh(bool checkSensors) noexcept
 		reqVal = 0.0;
 		const bool bangBangMode = (triggerTemperatures[1] <= triggerTemperatures[0]);
 		sensorsMonitored.Iterate
-		([&reqVal, bangBangMode, this
-#if HAS_SMART_DRIVERS
-		  , &driverChannelsMonitored
-#endif
-		 ](unsigned int sensorNum, unsigned int) noexcept
+		([&reqVal, bangBangMode, this](unsigned int sensorNum, unsigned int) noexcept
 			{
 				const auto sensor = reprap.GetHeat().FindSensor(sensorNum);
 				if (sensor.IsNotNull())
@@ -120,13 +113,6 @@ void LocalFan::InternalRefresh(bool checkSensors) noexcept
 							reqVal = newVal;
 						}
 					}
-#if HAS_SMART_DRIVERS
-					const int channel = sensor->GetSmartDriversChannel();
-					if (channel >= 0)
-					{
-						driverChannelsMonitored.SetBit((unsigned int)channel);
-					}
-#endif
 				}
 			}
 		);
@@ -137,12 +123,6 @@ void LocalFan::InternalRefresh(bool checkSensors) noexcept
 		if (lastVal <= 0.0)
 		{
 			// We are turning this fan on
-#if HAS_SMART_DRIVERS
-			if (driverChannelsMonitored.IsNonEmpty())
-			{
-				reprap.GetPlatform().DriverCoolingFansOnOff(driverChannelsMonitored, true);		// tell Platform that we have started a fan that cools drivers
-			}
-#endif
 			if (reqVal < 1.0 && blipTime != 0)
 			{
 				// Starting the fan from standstill, so blip the fan
@@ -158,12 +138,6 @@ void LocalFan::InternalRefresh(bool checkSensors) noexcept
 	else
 	{
 		blipping = false;
-#if HAS_SMART_DRIVERS
-		if (driverChannelsMonitored.IsNonEmpty() && lastVal > 0.0)
-		{
-			reprap.GetPlatform().DriverCoolingFansOnOff(driverChannelsMonitored, false);	// tell Platform that we have stopped a fan that cools drivers
-		}
-#endif
 	}
 
 	lastVal = reqVal;
diff --git a/src/Platform/Event.cpp b/src/Platform/Event.cpp
index e6cc33b5..022836db 100644
--- a/src/Platform/Event.cpp
+++ b/src/Platform/Event.cpp
@@ -60,6 +60,19 @@ inline Event::Event(Event *_ecv_null p_next, EventType et, uint16_t p_param, uin
 	return true;
 }
 
+#if SUPPORT_CAN_EXPANSION
+
+// Queue an event received via CAN
+/*static*/ void Event::Add(const CanMessageEvent& msg, CanAddress src, size_t msgLen) noexcept
+{
+	// We need to make sure that the text is null terminated
+	String<StringLength100> msgText;
+	msgText.copy(msg.text, msg.GetMaxTextLength(msgLen));
+	(void)AddEvent((EventType)msg.eventType, msg.eventParam, src, msg.deviceNumber, "%s", msgText.c_str());
+}
+
+#endif
+
 // Get the highest priority event and mark it as being serviced
 /*static*/ bool Event::StartProcessing() noexcept
 {
diff --git a/src/Platform/Event.h b/src/Platform/Event.h
index 81fb2a60..7e120095 100644
--- a/src/Platform/Event.h
+++ b/src/Platform/Event.h
@@ -32,6 +32,7 @@
 #include <Platform/PrintPausedReason.h>
 
 class VariableSet;
+class CanMessageEvent;
 
 class Event
 {
@@ -48,6 +49,11 @@ public:
 	// Queue an event, or release it if we have a similar event pending already. Returns true if the event was added, false if it was released.
 	static bool AddEventV(EventType et, uint16_t p_param, CanAddress p_ba, uint8_t devNum, const char *_ecv_array format, va_list vargs) noexcept;
 
+#if SUPPORT_CAN_EXPANSION
+	// Queue an event received via CAN
+	static void Add(const CanMessageEvent& msg, CanAddress src, size_t msgLen) noexcept;
+#endif
+
 	// Get the highest priority event if there is one start processing it
 	static bool StartProcessing() noexcept;
 
diff --git a/src/Platform/Platform.cpp b/src/Platform/Platform.cpp
index 58dc2a2a..7c8b9a8b 100644
--- a/src/Platform/Platform.cpp
+++ b/src/Platform/Platform.cpp
@@ -725,14 +725,9 @@ void Platform::Init() noexcept
 	temperatureShutdownDrivers.Clear();
 	temperatureWarningDrivers.Clear();
 	shortToGroundDrivers.Clear();
-	openLoadADrivers.Clear();
-	openLoadBDrivers.Clear();
-	notOpenLoadADrivers.Clear();
-	notOpenLoadBDrivers.Clear();
 #endif
 
 #if HAS_STALL_DETECT
-	stalledDrivers.Clear();
 	logOnStallDrivers.Clear();
 	eventOnStallDrivers.Clear();
 #endif
@@ -1088,16 +1083,25 @@ void Platform::Spin() noexcept
 			// Check one TMC2660 or TMC2224 for temperature warning or temperature shutdown
 			if (enableValues[nextDriveToPoll] >= 0)					// don't poll driver if it is flagged "no poll"
 			{
-				const StandardDriverStatus stat = SmartDrivers::GetStatus(nextDriveToPoll, true, true);
+				StandardDriverStatus stat = SmartDrivers::GetStatus(nextDriveToPoll, true, true);
 				const DriversBitmap mask = DriversBitmap::MakeFromBits(nextDriveToPoll);
 				if (stat.ot)
 				{
 					temperatureShutdownDrivers |= mask;
 				}
-				else if (stat.otpw)
+				else
 				{
-					temperatureWarningDrivers |= mask;
+					temperatureShutdownDrivers &= ~mask;
+					if (stat.otpw)
+					{
+						temperatureWarningDrivers |= mask;
+					}
+					else
+					{
+						temperatureWarningDrivers &= ~mask;
+					}
 				}
+
 				if (stat.s2ga || stat.s2gb || stat.s2vsa || stat.s2vsb)
 				{
 					shortToGroundDrivers |= mask;
@@ -1107,73 +1111,80 @@ void Platform::Spin() noexcept
 					shortToGroundDrivers &= ~mask;
 				}
 
+				// Deal with the open load bits
 				// The driver often produces a transient open-load error, especially in stealthchop mode, so we require the condition to persist before we report it.
-				// Also, false open load indications persist when in standstill, if the phase has zero current in that position
-				if (stat.ola)
+				// So clear them unless they have been active for the minimum time.
+				MillisTimer& timer = openLoadTimers[nextDriveToPoll];
+				if (stat.IsAnyOpenLoadBitSet())
 				{
-					if (!openLoadATimer.IsRunning())
+					if (timer.IsRunning())
 					{
-						openLoadATimer.Start();
-						openLoadADrivers.Clear();
-						notOpenLoadADrivers.Clear();
+						if (!timer.Check(OpenLoadTimeout))
+						{
+							stat.ClearOpenLoadBits();
+						}
 					}
-					openLoadADrivers |= mask;
-				}
-				else if (openLoadATimer.IsRunning())
-				{
-					notOpenLoadADrivers |= mask;
-					if (openLoadADrivers.Disjoint(~notOpenLoadADrivers))
+					else
 					{
-						openLoadATimer.Stop();
+						timer.Start();
+						stat.ClearOpenLoadBits();
 					}
 				}
+				else
+				{
+					timer.Stop();
+				}
 
-				if (stat.olb)
+				const StandardDriverStatus oldStatus = lastEventStatus[nextDriveToPoll];
+				lastEventStatus[nextDriveToPoll] = stat;
+				if (stat.HasNewErrorSince(oldStatus))
 				{
-					if (!openLoadBTimer.IsRunning())
+					// It's a new error
+# if SUPPORT_REMOTE_COMMANDS
+					if (CanInterface::InExpansionMode())
 					{
-						openLoadBTimer.Start();
-						openLoadBDrivers.Clear();
-						notOpenLoadBDrivers.Clear();
+						CanInterface::RaiseEvent(EventType::driver_error, stat.AsU16(), nextDriveToPoll, "", va_list());
+					}
+					else
+#endif
+					{
+						Event::AddEvent(EventType::driver_error, stat.AsU16(), CanInterface::GetCanAddress(), nextDriveToPoll, "");
 					}
-					openLoadBDrivers |= mask;
 				}
-				else if (openLoadBTimer.IsRunning())
+				else if (stat.HasNewWarningSince(oldStatus))
 				{
-					notOpenLoadBDrivers |= mask;
-					if (openLoadBDrivers.Disjoint(~notOpenLoadBDrivers))
+					// It's a new warning
+# if SUPPORT_REMOTE_COMMANDS
+					if (CanInterface::InExpansionMode())
 					{
-						openLoadBTimer.Stop();
+						CanInterface::RaiseEvent(EventType::driver_warning, stat.AsU16(), nextDriveToPoll, "", va_list());
+					}
+					else
+#endif
+					{
+						Event::AddEvent(EventType::driver_warning, stat.AsU16(), CanInterface::GetCanAddress(), nextDriveToPoll, "");
 					}
 				}
 
 # if HAS_STALL_DETECT
-				if (stat.stall)
+				if (stat.HasNewStallSince(oldStatus) && reprap.GetGCodes().IsReallyPrinting())
 				{
-					if (stalledDrivers.Disjoint(mask) && reprap.GetGCodes().IsReallyPrinting())
-					{
-						// This stall is new so check whether we need to perform some action in response to the stall
+					// This stall is new so check whether we need to perform some action in response to the stall
 #  if SUPPORT_REMOTE_COMMANDS
-						if (CanInterface::InExpansionMode())
-						{
-							CanInterface::RaiseEvent(EventType::driver_stall, 0, nextDriveToPoll, "", va_list());
-						}
-						else
+					if (CanInterface::InExpansionMode())
+					{
+						CanInterface::RaiseEvent(EventType::driver_stall, 0, nextDriveToPoll, "", va_list());
+					}
+					else
 #  endif
-						if (eventOnStallDrivers.Intersects(mask))
-						{
-							Event::AddEvent(EventType::driver_stall, 0, CanInterface::GetCanAddress(), nextDriveToPoll, "");
-						}
-						else if (logOnStallDrivers.Intersects(mask))
-						{
-							MessageF(WarningMessage, "Driver %u stalled at Z height %.2f", nextDriveToPoll, (double)reprap.GetMove().LiveCoordinate(Z_AXIS, reprap.GetCurrentTool()));
-						}
+					if (eventOnStallDrivers.Intersects(mask))
+					{
+						Event::AddEvent(EventType::driver_stall, 0, CanInterface::GetCanAddress(), nextDriveToPoll, "");
+					}
+					else if (logOnStallDrivers.Intersects(mask))
+					{
+						MessageF(WarningMessage, "Driver %u stalled at Z height %.2f", nextDriveToPoll, (double)reprap.GetMove().LiveCoordinate(Z_AXIS, reprap.GetCurrentTool()));
 					}
-					stalledDrivers |= mask;
-				}
-				else
-				{
-					stalledDrivers &= ~mask;
 				}
 # endif
 			}
@@ -1207,15 +1218,13 @@ void Platform::Spin() noexcept
 	{
 		driversPowered = true;
 #if HAS_SMART_DRIVERS
-		openLoadATimer.Stop();
-		openLoadBTimer.Stop();
+		for (size_t i= 0; i < MaxSmartDrivers; ++i)
+		{
+			openLoadTimers[i].Stop();
+		}
 		temperatureShutdownDrivers.Clear();
 		temperatureWarningDrivers.Clear();
 		shortToGroundDrivers.Clear();
-		openLoadADrivers.Clear();
-		openLoadBDrivers.Clear();
-		notOpenLoadADrivers.Clear();
-		notOpenLoadBDrivers.Clear();
 #endif
 	}
 
@@ -1249,43 +1258,6 @@ void Platform::Spin() noexcept
 		if (now - lastDriverPollMillis > MinimumWarningInterval)
 		{
 			bool reported = false;
-#if HAS_SMART_DRIVERS
-			ReportDrivers(ErrorMessage, shortToGroundDrivers, "short-to-ground", reported);
-			ReportDrivers(ErrorMessage, temperatureShutdownDrivers, "over temperature shutdown", reported);
-			if (openLoadATimer.CheckAndStop(OpenLoadTimeout))
-			{
-				ReportDrivers(WarningMessage, openLoadADrivers, "motor phase A may be disconnected", reported);
-			}
-			if (openLoadBTimer.CheckAndStop(OpenLoadTimeout))
-			{
-				ReportDrivers(WarningMessage, openLoadBDrivers, "motor phase B may be disconnected", reported);
-			}
-
-			// Don't warn about a hot driver if we recently turned on a fan to cool it
-			if (temperatureWarningDrivers.IsNonEmpty())
-			{
-				const DriversBitmap driversMonitored[NumTmcDriversSenseChannels] =
-# ifdef DUET_NG
-					{ DriversBitmap::MakeLowestNBits(5), DriversBitmap::MakeLowestNBits(5).ShiftUp(5) };			// first channel is Duet, second is DueX5
-# elif defined(DUET_M)
-					{ DriversBitmap::MakeLowestNBits(5), DriversBitmap::MakeLowestNBits(2).ShiftUp(5) };			// first channel is Duet, second is daughter board
-# else
-					{ DriversBitmap::MakeLowestNBits(NumDirectDrivers) };
-# endif
-				for (unsigned int i = 0; i < NumTmcDriversSenseChannels; ++i)
-				{
-					if (driversFanTimers[i].IsRunning())
-					{
-						const bool timedOut = driversFanTimers[i].CheckAndStop(DriverCoolingTimeout);
-						if (!timedOut)
-						{
-							temperatureWarningDrivers &= ~driversMonitored[i];
-						}
-					}
-				}
-				ReportDrivers(WarningMessage, temperatureWarningDrivers, "high temperature", reported);
-			}
-#endif
 
 #if HAS_VOLTAGE_MONITOR
 			if (numVinOverVoltageEvents != previousVinOverVoltageEvents)
@@ -2374,28 +2346,6 @@ GCodeResult Platform::DiagnosticTest(GCodeBuffer& gb, const StringRef& reply, Ou
 	return GCodeResult::ok;
 }
 
-#if HAS_SMART_DRIVERS
-
-// This is called when a fan that monitors driver temperatures is turned on when it was off
-void Platform::DriverCoolingFansOnOff(DriverChannelsBitmap driverChannelsMonitored, bool on) noexcept
-{
-	driverChannelsMonitored.Iterate
-		([this, on](unsigned int i, unsigned int) noexcept
-			{
-				if (on)
-				{
-					this->driversFanTimers[i].Start();
-				}
-				else
-				{
-					this->driversFanTimers[i].Stop();
-				}
-			}
-		);
-}
-
-#endif
-
 // Get the index of the averaging filter for an analog port.
 // Note, the Thermistor code assumes that this is also the thermistor input number
 int Platform::GetAveragingFilterIndex(const IoPort& port) const noexcept
@@ -3005,8 +2955,10 @@ void Platform::SetEnableValue(size_t driver, int8_t eVal) noexcept
 			temperatureShutdownDrivers &= mask;
 			temperatureWarningDrivers &= mask;
 			shortToGroundDrivers &= mask;
-			openLoadADrivers &= mask;
-			openLoadBDrivers &= mask;
+			if (driver < MaxSmartDrivers)
+			{
+				openLoadTimers[driver].Stop();
+			}
 		}
 #endif
 	}
@@ -5044,7 +4996,7 @@ void Platform::SendDriversStatus(CanMessageBuffer& buf) noexcept
 	msg->SetStandardFields(MaxSmartDrivers);
 	for (size_t driver = 0; driver < MaxSmartDrivers; ++driver)
 	{
-		msg->data[driver] = SmartDrivers::GetStatus(driver);
+		msg->data[driver] = SmartDrivers::GetStatus(driver).AsU32();
 	}
 # else
 	msg->SetStandardFields(NumDrivers);
diff --git a/src/Platform/Platform.h b/src/Platform/Platform.h
index 2ccf6acc..fca11c6a 100644
--- a/src/Platform/Platform.h
+++ b/src/Platform/Platform.h
@@ -583,7 +583,6 @@ public:
 
 #if HAS_SMART_DRIVERS
 	float GetTmcDriversTemperature(unsigned int boardNumber) const noexcept;
-	void DriverCoolingFansOnOff(DriverChannelsBitmap driverChannelsMonitored, bool on) noexcept;
 	unsigned int GetNumSmartDrivers() const noexcept { return numSmartDrivers; }
 #endif
 
@@ -758,11 +757,10 @@ private:
 	float minimumMovementSpeed;								// minimum allowed movement speed in mm per step clock
 
 #if HAS_SMART_DRIVERS
-	size_t numSmartDrivers;									// the number of TMC drivers we have, the remaining are simple enable/step/dir drivers
+	size_t numSmartDrivers;											// the number of TMC drivers we have, the remaining are simple enable/step/dir drivers
 	DriversBitmap temperatureShutdownDrivers, temperatureWarningDrivers, shortToGroundDrivers;
-	DriversBitmap openLoadADrivers, openLoadBDrivers, notOpenLoadADrivers, notOpenLoadBDrivers;
-	MillisTimer openLoadATimer, openLoadBTimer;
-	MillisTimer driversFanTimers[NumTmcDriversSenseChannels];		// driver cooling fan timers
+	MillisTimer openLoadTimers[MaxSmartDrivers];
+	StandardDriverStatus lastEventStatus[MaxSmartDrivers];
 	uint8_t nextDriveToPoll;
 #endif
 
@@ -774,7 +772,6 @@ private:
 
 #if HAS_STALL_DETECT
 	DriversBitmap logOnStallDrivers, eventOnStallDrivers;
-	DriversBitmap stalledDrivers;
 #endif
 
 #if defined(__LPC17xx__)
diff --git a/src/Version.h b/src/Version.h
index fa5b9479..df884df1 100644
--- a/src/Version.h
+++ b/src/Version.h
@@ -10,7 +10,7 @@
 
 #ifndef VERSION
 // Note: the complete VERSION string must be in standard version number format and must not contain spaces! This is so that DWC can parse it.
-# define MAIN_VERSION	"3.4.0beta6+3"
+# define MAIN_VERSION	"3.4.0beta7"
 # ifdef USE_CAN0
 #  define VERSION_SUFFIX	"(CAN0)"
 # else