Implemented heater feedforward for fan RPM changes

10 files changed, 54 insertions, 22 deletions

diff --git a/src/Heating/FOPDT.cpp b/src/Heating/FOPDT.cpp
index bb62bb9a..4c5e81fd 100644
--- a/src/Heating/FOPDT.cpp
+++ b/src/Heating/FOPDT.cpp
@@ -38,7 +38,7 @@ constexpr ObjectModelTableEntry FopDt::objectModelTable[] =
 	{ "pid",				OBJECT_MODEL_FUNC(self, 1),															ObjectModelEntryFlags::none },
 	{ "standardVoltage",	OBJECT_MODEL_FUNC(self->standardVoltage, 1),										ObjectModelEntryFlags::none },
 	{ "timeConstant",		OBJECT_MODEL_FUNC(self->GetTimeConstantFanOff(), 1),								ObjectModelEntryFlags::none },
-	{ "timeConstantFanOn",	OBJECT_MODEL_FUNC(self->GetTimeConstantFanOn(), 1),									ObjectModelEntryFlags::none },
+	{ "timeConstantFansOn",	OBJECT_MODEL_FUNC(self->GetTimeConstantFanOn(), 1),									ObjectModelEntryFlags::none },
 
 	// 1. PID members
 	{ "d",					OBJECT_MODEL_FUNC(self->loadChangeParams.tD * self->loadChangeParams.kP, 1),		ObjectModelEntryFlags::none },
@@ -58,7 +58,7 @@ DEFINE_GET_OBJECT_MODEL_TABLE(FopDt)
 // Set up sensible defaults here in case the user enables the heater without specifying values for all the parameters.
 FopDt::FopDt() noexcept
 	: heatingRate(DefaultHotEndHeaterHeatingRate),
-	  coolingRateFanOff(DefaultHotEndHeaterCoolingRate), coolingRateFanOn(DefaultHotEndHeaterCoolingRate),
+	  coolingRateFanOff(DefaultHotEndHeaterCoolingRate), coolingRateChangeFanOn(0.0),
 	  deadTime(DefaultHotEndHeaterDeadTime), maxPwm(1.0), standardVoltage(0.0),
 	  enabled(false), usePid(true), inverted(false), pidParametersOverridden(false)
 {
@@ -80,7 +80,7 @@ bool FopDt::SetParameters(float phr, float pcrFanOff, float pcrFanOn, float pdt,
 	{
 		heatingRate = phr;
 		coolingRateFanOff = pcrFanOff;
-		coolingRateFanOn = pcrFanOn;
+		coolingRateChangeFanOn = pcrFanOn - pcrFanOff;
 		deadTime = pdt;
 		maxPwm = pMaxPwm;
 		standardVoltage = pVoltage;
@@ -121,7 +121,7 @@ bool FopDt::WriteParameters(FileStore *f, size_t heater) const noexcept
 {
 	String<StringLength256> scratchString;
 	scratchString.printf("M307 H%u R%.3f C%.3f:%.3f D%.2f S%.2f V%.1f B%d\n",
-							heater, (double)heatingRate, (double)coolingRateFanOff, (double)coolingRateFanOn, (double)deadTime, (double)maxPwm, (double)standardVoltage, (usePid) ? 0 : 1);
+							heater, (double)heatingRate, (double)GetTimeConstantFanOff(), (double)GetTimeConstantFanOn(), (double)deadTime, (double)maxPwm, (double)standardVoltage, (usePid) ? 0 : 1);
 	bool ok = f->Write(scratchString.c_str());
 	if (ok && pidParametersOverridden)
 	{
@@ -166,7 +166,7 @@ bool FopDt::WriteParameters(FileStore *f, size_t heater) const noexcept
 
 void FopDt::CalcPidConstants() noexcept
 {
-	const float averageCoolingRate = (coolingRateFanOff + coolingRateFanOn) * 0.5;
+	const float averageCoolingRate = coolingRateFanOff + 0.5 * coolingRateChangeFanOn;
 	loadChangeParams.kP = 0.7/(heatingRate * deadTime);
 	loadChangeParams.recipTi = powf(averageCoolingRate, 0.25)/(1.14 * powf(deadTime, 0.75));	// Ti = 1.14 * timeConstant^0.25 * deadTime^0.75 (Ho et al)
 	loadChangeParams.tD = deadTime * 0.7;
@@ -180,11 +180,14 @@ void FopDt::CalcPidConstants() noexcept
 
 #if SUPPORT_CAN_EXPANSION
 
-void FopDt::SetupCanMessage(unsigned int heater, CanMessageUpdateHeaterModel& msg) const noexcept
+void FopDt::SetupCanMessage(unsigned int heater, CanMessageUpdateHeaterModelNew& msg) const noexcept
 {
 	msg.heater = heater;
-	msg.gain = gain;
-	msg.timeConstant = timeConstant;
+	msg.heatingRate = heatingRate;
+	msg.coolingRate = coolingRateFanOff;
+	msg.coolingRateChangeFanOn = coolingRateChangeFanOn;
+	msg.coolingRateChangeExtruding = 0.0;
+	msg.zero2 = 0.0;
 	msg.deadTime = deadTime;
 	msg.maxPwm = maxPwm;
 	msg.standardVoltage = standardVoltage;
diff --git a/src/Heating/FOPDT.h b/src/Heating/FOPDT.h
index 728b3c78..eab8d1fb 100644
--- a/src/Heating/FOPDT.h
+++ b/src/Heating/FOPDT.h
@@ -34,7 +34,7 @@ class FileStore;
 #endif
 
 #if SUPPORT_CAN_EXPANSION
-struct CanMessageUpdateHeaterModel;
+struct CanMessageUpdateHeaterModelNew;
 #endif
 
 class FopDt INHERIT_OBJECT_MODEL
@@ -47,7 +47,8 @@ public:
 	// Stored parameters
 	float GetHeatingRate() const noexcept { return heatingRate; }
 	float GetCoolingRateFanOff() const noexcept { return coolingRateFanOff; }
-	float GetCoolingRateFanOn() const noexcept { return coolingRateFanOn; }
+	float GetCoolingRateFanOn() const noexcept { return coolingRateFanOff + coolingRateChangeFanOn; }
+	float GetCoolingRateChangeFanOn() const noexcept { return coolingRateChangeFanOn; }
 	float GetDeadTime() const noexcept { return deadTime; }
 	float GetMaxPwm() const noexcept { return maxPwm; }
 	float GetVoltage() const noexcept { return standardVoltage; }
@@ -58,7 +59,7 @@ public:
 	// Derived parameters
 	float GetGainFanOff() const noexcept { return heatingRate/coolingRateFanOff; }
 	float GetTimeConstantFanOff() const noexcept { return 1.0/coolingRateFanOff; }
-	float GetTimeConstantFanOn() const noexcept { return 1.0/coolingRateFanOn; }
+	float GetTimeConstantFanOn() const noexcept { return 1.0/GetCoolingRateFanOn(); }
 	bool ArePidParametersOverridden() const noexcept { return pidParametersOverridden; }
 	M301PidParameters GetM301PidParameters(bool forLoadChange) const noexcept;
 	void SetM301PidParameters(const M301PidParameters& params) noexcept;
@@ -73,7 +74,7 @@ public:
 #endif
 
 #if SUPPORT_CAN_EXPANSION
-	void SetupCanMessage(unsigned int heater, CanMessageUpdateHeaterModel& msg) const noexcept;
+	void SetupCanMessage(unsigned int heater, CanMessageUpdateHeaterModelNew& msg) const noexcept;
 #endif
 
 protected:
@@ -84,7 +85,7 @@ private:
 
 	float heatingRate;
 	float coolingRateFanOff;
-	float coolingRateFanOn;
+	float coolingRateChangeFanOn;
 	float deadTime;
 	float maxPwm;
 	float standardVoltage;					// power voltage reading at which tuning was done, or 0 if unknown
diff --git a/src/Heating/Heat.cpp b/src/Heating/Heat.cpp
index bdd8bf1a..2a3d8e94 100644
--- a/src/Heating/Heat.cpp
+++ b/src/Heating/Heat.cpp
@@ -727,6 +727,15 @@ void Heat::Standby(int heater, const Tool *tool) noexcept
 	}
 }
 
+void Heat::PrintCoolingFanPwmChanged(unsigned int heater, float pwmChange) const noexcept
+{
+	const auto h = FindHeater(heater);
+	if (h.IsNotNull())
+	{
+		h->PrintCoolingFanPwmChanged(pwmChange);
+	}
+}
+
 GCodeResult Heat::ResetFault(int heater, const StringRef& reply) noexcept
 {
 	// This gets called for all heater numbers when clearing all temperature faults, so don't report an error if the heater was not found
diff --git a/src/Heating/Heat.h b/src/Heating/Heat.h
index bbe9bff9..74bccc26 100644
--- a/src/Heating/Heat.h
+++ b/src/Heating/Heat.h
@@ -131,6 +131,7 @@ public:
 	GCodeResult Activate(int heater, const StringRef& reply) noexcept;	// Turn on a heater
 	void Standby(int heater, const Tool* tool) noexcept;				// Set a heater to standby
 	void SwitchOff(int heater) noexcept;								// Turn off a specific heater
+	void PrintCoolingFanPwmChanged(unsigned int heater, float pwmChange) const noexcept;
 
 #if HAS_MASS_STORAGE
 	bool WriteModelParameters(FileStore *f) const noexcept;				// Write heater model parameters to file returning true if no error
diff --git a/src/Heating/Heater.cpp b/src/Heating/Heater.cpp
index 4d7133bf..9a862383 100644
--- a/src/Heating/Heater.cpp
+++ b/src/Heating/Heater.cpp
@@ -179,17 +179,17 @@ GCodeResult Heater::SetOrReportModel(unsigned int heater, GCodeBuffer& gb, const
 }
 
 // Set the process model returning true if successful
-GCodeResult Heater::SetModel(float gain, float tcOff, float tcOn, float td, float maxPwm, float voltage, bool usePid, bool inverted, const StringRef& reply) noexcept
+GCodeResult Heater::SetModel(float heatingRate, float coolingRateFanOff, float coolingRateFanOn, float td, float maxPwm, float voltage, bool usePid, bool inverted, const StringRef& reply) noexcept
 {
 	GCodeResult rslt;
-	if (model.SetParameters(gain, tcOff, tcOn, td, maxPwm, GetHighestTemperatureLimit(), voltage, usePid, inverted))
+	if (model.SetParameters(heatingRate, coolingRateFanOff, coolingRateFanOn, td, maxPwm, GetHighestTemperatureLimit(), voltage, usePid, inverted))
 	{
 		if (model.IsEnabled())
 		{
 			rslt = UpdateModel(reply);
 			if (rslt == GCodeResult::ok)
 			{
-				const float predictedMaxTemp = gain + NormalAmbientTemperature;
+				const float predictedMaxTemp = heatingRate/coolingRateFanOff + NormalAmbientTemperature;
 				const float noWarnTemp = (GetHighestTemperatureLimit() - NormalAmbientTemperature) * 1.5 + 50.0;		// allow 50% extra power plus enough for an extra 50C
 				if (predictedMaxTemp > noWarnTemp)
 				{
diff --git a/src/Heating/Heater.h b/src/Heating/Heater.h
index 502e2e74..8c8231e0 100644
--- a/src/Heating/Heater.h
+++ b/src/Heating/Heater.h
@@ -43,9 +43,10 @@ public:
 	virtual void SwitchOff() noexcept = 0;
 	virtual void Spin() noexcept = 0;
 	virtual GCodeResult StartAutoTune(GCodeBuffer& gb, const StringRef& reply) THROWS(GCodeException) = 0;	// Start an auto tune cycle for this heater
-	virtual void GetAutoTuneStatus(const StringRef& reply) const = 0;	// Get the auto tune status or last result
+	virtual void GetAutoTuneStatus(const StringRef& reply) const noexcept = 0;	// Get the auto tune status or last result
 	virtual void Suspend(bool sus) noexcept = 0;						// Suspend the heater to conserve power or while doing Z probing
 	virtual float GetAccumulator() const noexcept = 0;					// Get the inertial term accumulator
+	virtual void PrintCoolingFanPwmChanged(float pwmChange) noexcept = 0;
 
 #if SUPPORT_CAN_EXPANSION
 	virtual void UpdateRemoteStatus(CanAddress src, const CanHeaterReport& report) noexcept = 0;
@@ -117,7 +118,7 @@ protected:
 	float GetMaxTemperatureExcursion() const noexcept { return maxTempExcursion; }
 	float GetMaxHeatingFaultTime() const noexcept { return maxHeatingFaultTime; }
 	float GetTargetTemperature() const noexcept { return (active) ? activeTemperature : standbyTemperature; }
-	GCodeResult SetModel(float gain, float tcOff, float tcOn, float td, float maxPwm, float voltage, bool usePid, bool inverted, const StringRef& reply) noexcept;	// Set the process model
+	GCodeResult SetModel(float heatingRate, float coolingRateFanOff, float coolingRateFanOn, float td, float maxPwm, float voltage, bool usePid, bool inverted, const StringRef& reply) noexcept;	// Set the process model
 
 	HeaterMonitor monitors[MaxMonitorsPerHeater];	// embedding them in the Heater uses less memory than dynamic allocation
 
diff --git a/src/Heating/LocalHeater.cpp b/src/Heating/LocalHeater.cpp
index d5764c04..1d0af3f3 100644
--- a/src/Heating/LocalHeater.cpp
+++ b/src/Heating/LocalHeater.cpp
@@ -596,6 +596,16 @@ void LocalHeater::GetAutoTuneStatus(const StringRef& reply) const noexcept
 	}
 }
 
+// Call this when the PWM of a cooling fan has changed. If there are multiple fans, caller must divide pwmChange by the number of fans.
+void LocalHeater::PrintCoolingFanPwmChanged(float pwmChange) noexcept
+{
+	if (mode == HeaterMode::stable)
+	{
+		const float coolingRateIncrease = GetModel().GetCoolingRateChangeFanOn() * pwmChange;
+		iAccumulator += (coolingRateIncrease * (GetTargetTemperature() - NormalAmbientTemperature))/GetModel().GetHeatingRate();
+	}
+}
+
 /* Notes on the auto tune algorithm
  *
  * Most 3D printer firmwares use the �str�m-H�gglund relay tuning method (sometimes called Ziegler-Nichols + relay).
diff --git a/src/Heating/LocalHeater.h b/src/Heating/LocalHeater.h
index 8c32dc39..5cad973b 100644
--- a/src/Heating/LocalHeater.h
+++ b/src/Heating/LocalHeater.h
@@ -50,6 +50,7 @@ public:
 	GCodeResult StartAutoTune(GCodeBuffer& gb, const StringRef& reply) THROWS(GCodeException) override;	// Start an auto tune cycle for this heater
 	void GetAutoTuneStatus(const StringRef& reply) const noexcept override;	// Get the auto tune status or last result
 	void Suspend(bool sus) noexcept override;				// Suspend the heater to conserve power or while doing Z probing
+	void PrintCoolingFanPwmChanged(float pwmChange) noexcept override;
 
 #if SUPPORT_CAN_EXPANSION
 	void UpdateRemoteStatus(CanAddress src, const CanHeaterReport& report) noexcept override { }
diff --git a/src/Heating/RemoteHeater.cpp b/src/Heating/RemoteHeater.cpp
index 70dfe8bb..94e6f377 100644
--- a/src/Heating/RemoteHeater.cpp
+++ b/src/Heating/RemoteHeater.cpp
@@ -41,13 +41,13 @@ void RemoteHeater::ResetHeater() noexcept
 	//TODO
 }
 
-GCodeResult RemoteHeater::ConfigurePortAndSensor(const char *portName, PwmFrequency freq, unsigned int sensorNumber, const StringRef& reply)
+GCodeResult RemoteHeater::ConfigurePortAndSensor(const char *portName, PwmFrequency freq, unsigned int sn, const StringRef& reply)
 {
-	SetSensorNumber(sensorNumber);
+	SetSensorNumber(sn);
 	CanMessageGenericConstructor cons(M950HeaterParams);
 	cons.AddUParam('H', GetHeaterNumber());
 	cons.AddUParam('Q', freq);
-	cons.AddUParam('T', sensorNumber);
+	cons.AddUParam('T', sn);
 	cons.AddStringParam('C', portName);
 	return cons.SendAndGetResponse(CanMessageType::m950Heater, boardAddress, reply);
 }
@@ -139,6 +139,11 @@ void RemoteHeater::GetAutoTuneStatus(const StringRef& reply) const noexcept
 	reply.copy("remote heater auto tune not implemented");
 }
 
+void RemoteHeater::PrintCoolingFanPwmChanged(float pwmChange) noexcept
+{
+	//TODO send a CAN message to remote
+}
+
 void RemoteHeater::Suspend(bool sus) noexcept
 {
 	CanMessageBuffer * const buf = CanMessageBuffer::Allocate();
@@ -189,7 +194,7 @@ GCodeResult RemoteHeater::UpdateModel(const StringRef& reply) noexcept
 	if (buf != nullptr)
 	{
 		const CanRequestId rid = CanInterface::AllocateRequestId(boardAddress);
-		CanMessageUpdateHeaterModel * const msg = buf->SetupRequestMessage<CanMessageUpdateHeaterModel>(rid, CanInterface::GetCanAddress(), boardAddress);
+		CanMessageUpdateHeaterModelNew * const msg = buf->SetupRequestMessage<CanMessageUpdateHeaterModelNew>(rid, CanInterface::GetCanAddress(), boardAddress);
 		GetModel().SetupCanMessage(GetHeaterNumber(), *msg);
 		return CanInterface::SendRequestAndGetStandardReply(buf, rid, reply);
 	}
diff --git a/src/Heating/RemoteHeater.h b/src/Heating/RemoteHeater.h
index 676dfdfa..558b49b4 100644
--- a/src/Heating/RemoteHeater.h
+++ b/src/Heating/RemoteHeater.h
@@ -31,6 +31,7 @@ public:
 	GCodeResult StartAutoTune(GCodeBuffer& gb, const StringRef& reply) THROWS(GCodeException) override;	// Start an auto tune cycle for this heater
 	void GetAutoTuneStatus(const StringRef& reply) const noexcept override;	// Get the auto tune status or last result
 	void Suspend(bool sus) noexcept override;				// Suspend the heater to conserve power or while doing Z probing
+	void PrintCoolingFanPwmChanged(float pwmChange) noexcept override;
 	void UpdateRemoteStatus(CanAddress src, const CanHeaterReport& report) noexcept override;
 
 protected: