Filament monitor and DDA changes

Removed code for early allocation of DriveMovement objects
Removed arrays of DriveMovement objects from DDAs
Fix for laser filament monitor overdue reports

6 files changed, 58 insertions, 48 deletions

diff --git a/src/FilamentMonitors/Duet3DFilamentMonitor.cpp b/src/FilamentMonitors/Duet3DFilamentMonitor.cpp
index 1ac42435..e698f66e 100644
--- a/src/FilamentMonitors/Duet3DFilamentMonitor.cpp
+++ b/src/FilamentMonitors/Duet3DFilamentMonitor.cpp
@@ -13,7 +13,7 @@
 
 // Constructors
 Duet3DFilamentMonitor::Duet3DFilamentMonitor(unsigned int extruder, int type)
-	: FilamentMonitor(extruder, type)
+	: FilamentMonitor(extruder, type), overrunErrorCount(0), polarityErrorCount(0)
 {
 	InitReceiveBuffer();
 }
@@ -37,6 +37,7 @@ bool Duet3DFilamentMonitor::Interrupt()
 		{
 			if ((writePointer & 1) == 0)							// low-to-high transitions should occur on odd indices
 			{
+				++polarityErrorCount;
 				return false;
 			}
 			if (state == RxdState::waitingForStartBit && writePointer == edgeCaptureReadPointer && !HaveIsrStepsCommanded())
@@ -48,6 +49,7 @@ bool Duet3DFilamentMonitor::Interrupt()
 		{
 			if ((writePointer & 1) != 0)							// high-to-low transitions should occur on even indices
 			{
+				++polarityErrorCount;
 				return false;
 			}
 			now -= 40;												// partial correction for skew caused by debounce filter on older Duet endstop inputs (measured skew = 74)
@@ -56,6 +58,10 @@ bool Duet3DFilamentMonitor::Interrupt()
 		edgeCaptures[writePointer] = now;							// record the time at which this edge was detected
 		edgeCaptureWritePointer = (writePointer + 1) % EdgeCaptureBufferSize;
 	}
+	else
+	{
+		++overrunErrorCount;
+	}
 	return wantReading;
 }
 
@@ -63,11 +69,11 @@ bool Duet3DFilamentMonitor::Interrupt()
 Duet3DFilamentMonitor::PollResult Duet3DFilamentMonitor::PollReceiveBuffer(uint16_t& measurement)
 {
 	// For the Duet3D sensors we need to decode the received data from the transition times recorded in the edgeCaptures array
-	static constexpr uint32_t BitsPerSecond = 1000;									// the nominal bit rate that the data is transmitted at
-	static constexpr uint32_t NominalBitLength = StepTimer::StepClockRate/BitsPerSecond;		// the nominal bit length in step clocks
-	static constexpr uint32_t MinBitLength = (NominalBitLength * 10)/13;			// allow 30% clock speed tolerance
-	static constexpr uint32_t MaxBitLength = (NominalBitLength * 13)/10;			// allow 30% clock speed tolerance
-	static constexpr uint32_t ErrorRecoveryDelayBits = 8;							// before a start bit we want the line to be low for this long
+	static constexpr uint32_t BitsPerSecond = 1000;							// the nominal bit rate that the data is transmitted at
+	static constexpr uint32_t NominalBitLength = StepTimer::StepClockRate/BitsPerSecond;	// the nominal bit length in step clocks
+	static constexpr uint32_t MinBitLength = (NominalBitLength * 10)/13;	// allow 30% clock speed tolerance
+	static constexpr uint32_t MaxBitLength = (NominalBitLength * 13)/10;	// allow 30% clock speed tolerance
+	static constexpr uint32_t ErrorRecoveryDelayBits = 8;					// before a start bit we want the line to be low for this long
 	static constexpr uint32_t ErrorRecoveryTime = NominalBitLength * ErrorRecoveryDelayBits;
 
 	bool again;
@@ -118,7 +124,6 @@ Duet3DFilamentMonitor::PollResult Duet3DFilamentMonitor::PollReceiveBuffer(uint1
 					nibblesAssembled = 0;
 					state = RxdState::waitingForNibble;
 					again = true;
-					//debugPrintf("sb %u\n", startBitLength);
 				}
 				else
 				{
@@ -153,6 +158,7 @@ Duet3DFilamentMonitor::PollResult Duet3DFilamentMonitor::PollReceiveBuffer(uint1
 							nextBitChangeIndex = (lastBitChangeIndex + 1u) % EdgeCaptureBufferSize;
 							if (nextBitChangeIndex != writePointer && edgeCaptures[nextBitChangeIndex] - nibbleStartTime < samplePoint)
 							{
+								// We recorded two edges within one sample period
 								edgeCaptureReadPointer = nextBitChangeIndex;
 								state = RxdState::errorRecovery3;
 								again = true;
diff --git a/src/FilamentMonitors/Duet3DFilamentMonitor.h b/src/FilamentMonitors/Duet3DFilamentMonitor.h
index 214f7d6c..4456a87e 100644
--- a/src/FilamentMonitors/Duet3DFilamentMonitor.h
+++ b/src/FilamentMonitors/Duet3DFilamentMonitor.h
@@ -32,6 +32,10 @@ protected:
 	bool IsReceiving() const;
 	bool IsWaitingForStartBit() const;
 
+protected:
+	uint32_t overrunErrorCount;
+	uint32_t polarityErrorCount;
+
 private:
 	static constexpr size_t EdgeCaptureBufferSize = 64;				// must be a power of 2
 
@@ -42,7 +46,7 @@ private:
 
 	enum class RxdState : uint8_t
 	{
-		waitingForStartBit,
+		waitingForStartBit = 0,
 		waitingForEndOfStartBit,
 		waitingForNibble,
 		errorRecovery1,
@@ -51,12 +55,12 @@ private:
 		errorRecovery4
 	};
 
-	RxdState state;
 	uint32_t startBitLength;
 	uint32_t errorRecoveryStartTime;
 	size_t lastBitChangeIndex;
 	uint16_t valueBeingAssembled;
 	uint8_t nibblesAssembled;
+	RxdState state;
 };
 
 #endif /* SRC_FILAMENTSENSORS_DUET3DFILAMENTMONITOR_H_ */
diff --git a/src/FilamentMonitors/LaserFilamentMonitor.cpp b/src/FilamentMonitors/LaserFilamentMonitor.cpp
index 31f4f8e4..84cf4f94 100644
--- a/src/FilamentMonitors/LaserFilamentMonitor.cpp
+++ b/src/FilamentMonitors/LaserFilamentMonitor.cpp
@@ -28,7 +28,7 @@ LaserFilamentMonitor::LaserFilamentMonitor(unsigned int extruder, int type)
 void LaserFilamentMonitor::Init()
 {
 	sensorValue = 0;
-	parityErrorCount = framingErrorCount = 0;
+	parityErrorCount = framingErrorCount = overrunErrorCount = polarityErrorCount = overdueCount = 0;
 	lastMeasurementTime = 0;
 	imageQuality = shutter = brightness = lastErrorCode = 0;
 	version = 1;
@@ -287,7 +287,10 @@ FilamentSensorStatus LaserFilamentMonitor::Check(bool isPrinting, bool fromIsr,
 		ret = CheckFilament(extrusionCommandedThisSegment, movementMeasuredThisSegment, false);
 		extrusionCommandedThisSegment = movementMeasuredThisSegment = 0.0;
 	}
-	else if (extrusionCommandedThisSegment + extrusionCommandedSinceLastSync >= minimumExtrusionCheckLength * 2 && millis() - lastMeasurementTime > 220 && !IsReceiving())
+	else if (   extrusionCommandedThisSegment + extrusionCommandedSinceLastSync >= minimumExtrusionCheckLength * 3
+			 && millis() - lastMeasurementTime > 500
+			 && !IsReceiving()
+			)
 	{
 		// A sync is overdue
 		ret = CheckFilament(extrusionCommandedThisSegment + extrusionCommandedSinceLastSync, movementMeasuredThisSegment + movementMeasuredSinceLastSync, true);
@@ -382,16 +385,9 @@ FilamentSensorStatus LaserFilamentMonitor::Clear()
 	Reset();							// call this first so that haveStartBitData and synced are false when we call HandleIncomingData
 	HandleIncomingData();
 
-	FilamentSensorStatus ret = FilamentSensorStatus::ok;
-	if (sensorError)
-	{
-		ret = FilamentSensorStatus::sensorError;
-	}
-	else if ((sensorValue & switchOpenMask) != 0)
-	{
-		ret = FilamentSensorStatus::noFilament;
-	}
-	return ret;
+	return (sensorError) ? FilamentSensorStatus::sensorError
+			: ((sensorValue & switchOpenMask) != 0) ? FilamentSensorStatus::noFilament
+				: FilamentSensorStatus::ok;
 }
 
 // Print diagnostic info for this sensor
@@ -401,14 +397,10 @@ void LaserFilamentMonitor::Diagnostics(MessageType mtype, unsigned int extruder)
 									: (sensorError) ? "error"
 										: ((sensorValue & switchOpenMask) != 0) ? "no filament"
 											: "ok";
-	reprap.GetPlatform().MessageF(mtype, "Extruder %u sensor: position %.2f, %s, ", extruder, (double)GetCurrentPosition(), statusText);
-	if (dataReceived)
-	{
-		reprap.GetPlatform().MessageF(mtype, "framing errors %" PRIu32 ", parity errors %" PRIu32 ", ", framingErrorCount, parityErrorCount);
-	}
+	reprap.GetPlatform().MessageF(mtype, "Extruder %u: pos %.2f, %s, ", extruder, (double)GetCurrentPosition(), statusText);
 	if (laserMonitorState != LaserMonitorState::calibrating && totalExtrusionCommanded > 10.0)
 	{
-		reprap.GetPlatform().MessageF(mtype, "measured minimum %ld%%, average %ld%%, maximum %ld%% over %.1fmm\n",
+		reprap.GetPlatform().MessageF(mtype, "measured min %ld%% avg %ld%% max %ld%% over %.1fmm",
 			lrintf(100 * minMovementRatio),
 			lrintf((100 * totalMovementMeasured)/totalExtrusionCommanded),
 			lrintf(100 * maxMovementRatio),
@@ -416,7 +408,16 @@ void LaserFilamentMonitor::Diagnostics(MessageType mtype, unsigned int extruder)
 	}
 	else
 	{
-		reprap.GetPlatform().Message(mtype, "no calibration data\n");
+		reprap.GetPlatform().Message(mtype, "no calibration data");
+	}
+	if (dataReceived)
+	{
+		reprap.GetPlatform().MessageF(mtype, ", errs: frame %" PRIu32 " parity %" PRIu32 " ovrun %" PRIu32 " pol %" PRIu32  " ovdue %" PRIu32 "\n",
+			framingErrorCount, parityErrorCount, overrunErrorCount, polarityErrorCount, overdueCount);
+	}
+	else
+	{
+		reprap.GetPlatform().Message(mtype, "\n");
 	}
 }
 
diff --git a/src/FilamentMonitors/LaserFilamentMonitor.h b/src/FilamentMonitors/LaserFilamentMonitor.h
index df03af13..4a441c2f 100644
--- a/src/FilamentMonitors/LaserFilamentMonitor.h
+++ b/src/FilamentMonitors/LaserFilamentMonitor.h
@@ -76,6 +76,7 @@ private:
 	// Other data
 	uint32_t framingErrorCount;								// the number of framing errors we received
 	uint32_t parityErrorCount;								// the number of words with bad parity we received
+	uint32_t overdueCount;									// the number of times a position report was overdue
 
 	uint32_t candidateStartBitTime;							// the time that we received a possible start bit
 	float extrusionCommandedAtCandidateStartBit;			// the amount of extrusion commanded since the previous comparison when we received the possible start bit
diff --git a/src/FilamentMonitors/RotatingMagnetFilamentMonitor.cpp b/src/FilamentMonitors/RotatingMagnetFilamentMonitor.cpp
index 1100a14e..2883bf7c 100644
--- a/src/FilamentMonitors/RotatingMagnetFilamentMonitor.cpp
+++ b/src/FilamentMonitors/RotatingMagnetFilamentMonitor.cpp
@@ -29,7 +29,7 @@ RotatingMagnetFilamentMonitor::RotatingMagnetFilamentMonitor(unsigned int extrud
 void RotatingMagnetFilamentMonitor::Init()
 {
 	sensorValue = 0;
-	framingErrorCount = 0;
+	framingErrorCount = overrunErrorCount = polarityErrorCount = overdueCount = 0;
 	calibrationStarted = dataReceived = false;
 	lastMeasurementTime = 0;
 	InitReceiveBuffer();
@@ -211,7 +211,10 @@ FilamentSensorStatus RotatingMagnetFilamentMonitor::Check(bool isPrinting, bool
 		ret = CheckFilament(extrusionCommandedThisSegment, movementMeasuredThisSegment, false);
 		extrusionCommandedThisSegment = movementMeasuredThisSegment = 0.0;
 	}
-	else if (extrusionCommandedThisSegment + extrusionCommandedSinceLastSync >= minimumExtrusionCheckLength * 2 && millis() - lastMeasurementTime > 220 && !IsReceiving())
+	else if (   extrusionCommandedThisSegment + extrusionCommandedSinceLastSync >= minimumExtrusionCheckLength * 3
+			 && millis() - lastMeasurementTime > 500
+			 && !IsReceiving()
+			)
 	{
 		// A sync is overdue
 		ret = CheckFilament(extrusionCommandedThisSegment + extrusionCommandedSinceLastSync, movementMeasuredThisSegment + movementMeasuredSinceLastSync, true);
@@ -288,19 +291,12 @@ FilamentSensorStatus RotatingMagnetFilamentMonitor::CheckFilament(float amountCo
 // Clear the measurement state - called when we are not printing a file. Return the present/not present status if available.
 FilamentSensorStatus RotatingMagnetFilamentMonitor::Clear()
 {
-	HandleIncomingData();								// to keep the diagnostics up to date
 	Reset();
+	HandleIncomingData();								// to keep the diagnostics up to date
 
-	FilamentSensorStatus ret = FilamentSensorStatus::ok;
-	if ((sensorValue & TypeMagnetErrorMask) != 0)
-	{
-		ret = FilamentSensorStatus::sensorError;
-	}
-	else if ((sensorValue & switchOpenMask) != 0)
-	{
-		ret = FilamentSensorStatus::noFilament;
-	}
-	return ret;
+	return ((sensorValue & TypeMagnetErrorMask) != 0) ? FilamentSensorStatus::sensorError
+			: ((sensorValue & switchOpenMask) != 0) ? FilamentSensorStatus::noFilament
+				: FilamentSensorStatus::ok;
 }
 
 // Print diagnostic info for this sensor
@@ -310,15 +306,11 @@ void RotatingMagnetFilamentMonitor::Diagnostics(MessageType mtype, unsigned int
 									: ((sensorValue & TypeMagnetErrorMask) != 0) ? "error"
 										: ((sensorValue & switchOpenMask) != 0) ? "no filament"
 											: "ok";
-	reprap.GetPlatform().MessageF(mtype, "Extruder %u sensor: position %.2f, %s, ", extruder, (double)GetCurrentPosition(), statusText);
-	if (dataReceived)
-	{
-		reprap.GetPlatform().MessageF(mtype, "%" PRIu32 " framing errors, ", framingErrorCount);
-	}
+	reprap.GetPlatform().MessageF(mtype, "Extruder %u: pos %.2f, %s, ", extruder, (double)GetCurrentPosition(), statusText);
 	if (calibrationStarted && fabsf(totalMovementMeasured) > 1.0 && totalExtrusionCommanded > 20.0)
 	{
 		const float measuredMmPerRev = totalExtrusionCommanded/totalMovementMeasured;
-		reprap.GetPlatform().MessageF(mtype, "measured sensitivity %.2fmm/rev, measured minimum %ld%%, maximum %ld%% over %.1fmm\n",
+		reprap.GetPlatform().MessageF(mtype, "measured sens %.2fmm/rev min %ld%% max %ld%% over %.1fmm",
 			(double)measuredMmPerRev,
 			lrintf(100 * minMovementRatio),
 			lrintf(100 * maxMovementRatio),
@@ -326,7 +318,12 @@ void RotatingMagnetFilamentMonitor::Diagnostics(MessageType mtype, unsigned int
 	}
 	else
 	{
-		reprap.GetPlatform().Message(mtype, "no calibration data\n");
+		reprap.GetPlatform().Message(mtype, "no calibration data");
+	}
+	if (dataReceived)
+	{
+		reprap.GetPlatform().MessageF(mtype, ", errs: frame %" PRIu32 " ovrun %" PRIu32 " pol %" PRIu32  " ovdue %" PRIu32 "\n",
+			framingErrorCount, overrunErrorCount, polarityErrorCount, overdueCount);
 	}
 }
 
diff --git a/src/FilamentMonitors/RotatingMagnetFilamentMonitor.h b/src/FilamentMonitors/RotatingMagnetFilamentMonitor.h
index 2b6eb1be..72acbbdb 100644
--- a/src/FilamentMonitors/RotatingMagnetFilamentMonitor.h
+++ b/src/FilamentMonitors/RotatingMagnetFilamentMonitor.h
@@ -45,6 +45,7 @@ private:
 
 	// Other data
 	uint32_t framingErrorCount;								// the number of framing errors we received
+	uint32_t overdueCount;									// the number of times a position report was overdue
 
 	uint32_t candidateStartBitTime;							// the time that we received a possible start bit
 	float extrusionCommandedAtCandidateStartBit;			// the amount of extrusion commanded since the previous comparison when we received the possible start bit