path: root/src/PrintMonitor.cpp

/****************************************************************************************************

RepRapFirmware - PrintMonitor

This class provides methods to obtain print end-time estimations and file information from generated
G-Code files, which may be reported to auxiliary devices and to the web interface using status responses.

-----------------------------------------------------------------------------------------------------

Version 0.1

Created on: Feb 24, 2015

Christian Hammacher

Licence: GPL

****************************************************************************************************/

#include "PrintMonitor.h"

#include "GCodes/GCodes.h"
#include "Heating/Heat.h"
#include "Movement/Move.h"
#include "Platform.h"
#include "RepRap.h"

PrintMonitor::PrintMonitor(Platform& p, GCodes& gc) : platform(p), gCodes(gc), isPrinting(false),
	printStartTime(0), pauseStartTime(0), totalPauseTime(0), heatingUp(false), currentLayer(0), warmUpDuration(0.0),
	firstLayerDuration(0.0), firstLayerFilament(0.0), firstLayerProgress(0.0), lastLayerChangeTime(0.0),
	lastLayerFilament(0.0), lastLayerZ(0.0), numLayerSamples(0), layerEstimatedTimeLeft(0.0), printingFileParsed(false)
{
	filenameBeingPrinted[0] = 0;
}

void PrintMonitor::Init()
{
	lastUpdateTime = millis();
}

// Get information for the specified file, or the currently printing file, in JSON format
bool PrintMonitor::GetPrintingFileInfoResponse(OutputBuffer *&response) const
{
	// If the file being printed hasn't been processed yet or if we cannot write the response, try again later
	if (!printingFileParsed || !OutputBuffer::Allocate(response))
	{
		return false;
	}

	// Poll file info about a file currently being printed
	response->printf("{\"err\":0,\"size\":%lu,\"height\":%.2f,\"firstLayerHeight\":%.2f,\"layerHeight\":%.2f,\"filament\":",
					printingFileInfo.fileSize, (double)printingFileInfo.objectHeight, (double)printingFileInfo.firstLayerHeight, (double)printingFileInfo.layerHeight);
	char ch = '[';
	if (printingFileInfo.numFilaments == 0)
	{
		response->cat(ch);
	}
	else
	{
		for (size_t i = 0; i < printingFileInfo.numFilaments; ++i)
		{
			response->catf("%c%.1f", ch, (double)printingFileInfo.filamentNeeded[i]);
			ch = ',';
		}
	}
	response->cat("],\"generatedBy\":");
	response->EncodeString(printingFileInfo.generatedBy.c_str(), printingFileInfo.generatedBy.Capacity(), false);
	response->catf(",\"printDuration\":%d,\"fileName\":", (int)GetPrintDuration());
	response->EncodeString(filenameBeingPrinted.c_str(), filenameBeingPrinted.Capacity(), false);
	response->cat('}');

	return true;
}

void PrintMonitor::Spin()
{
	// File information about the file being printed must be available before layer estimations can be made
	if (filenameBeingPrinted[0] != 0 && !printingFileParsed)
	{
		printingFileParsed = platform.GetMassStorage()->GetFileInfo(platform.GetGCodeDir(), filenameBeingPrinted.c_str(), printingFileInfo, false);
		if (!printingFileParsed)
		{
			return;
		}
	}

	// Don't do any updates if the print has been paused
	if (!gCodes.IsRunning())
	{
		if (pauseStartTime == 0)
		{
			pauseStartTime = millis64();
		}
		return;
	}

	// Otherwise collect some stats after a certain period of time
	uint32_t now = millis();
	if (IsPrinting()
#if SUPPORT_ROLAND
		&& !reprap.GetRoland()->Active()
#endif
		&& now - lastUpdateTime > PRINTMONITOR_UPDATE_INTERVAL)
	{
		// Adjust the actual print time if the print was paused before
		if (pauseStartTime != 0)
		{
			totalPauseTime += millis64() - pauseStartTime;
			pauseStartTime = 0;
		}

		// Have we just started a print? See if we're heating up
		if (currentLayer == 0)
		{
			// Check if there are any active heaters
			bool nozzleAtHighTemperature = false;
			for (int heater = 0; heater < (int)Heaters; heater++)
			{
				if (reprap.GetHeat().GetStatus(heater) == Heat::HS_active && reprap.GetHeat().GetActiveTemperature(heater) > TEMPERATURE_LOW_SO_DONT_CARE)
				{
					heatingUp = true;

					// Check if this heater is assigned to a tool and if it has reached its set temperature yet
					if (reprap.IsHeaterAssignedToTool(heater))
					{
						if (!reprap.GetHeat().HeaterAtSetTemperature(heater, false))
						{
							nozzleAtHighTemperature = false;
							break;
						}
						nozzleAtHighTemperature = true;
					}
				}
			}

			// Yes - do we have live movement?
			if (nozzleAtHighTemperature && !reprap.GetMove().NoLiveMovement())
			{
				// Yes - we're actually starting the print
				WarmUpComplete();
				currentLayer = 1;
			}
		}
		else if (!gCodes.DoingFileMacro() && reprap.GetMove().IsExtruding())
		{
			// Print is in progress and filament is being extruded
			float liveCoordinates[DRIVES];
			reprap.GetMove().LiveCoordinates(liveCoordinates, reprap.GetCurrentXAxes(), reprap.GetCurrentYAxes());

			if (currentLayer == 1)
			{
				// See if we need to determine the first layer height (usually smaller than the nozzle diameter)
				if (printingFileInfo.firstLayerHeight == 0.0 && liveCoordinates[Z_AXIS] < platform.GetNozzleDiameter() * 1.5)
				{
					// This shouldn't be needed because we parse the first layer height anyway, but it won't harm
					printingFileInfo.firstLayerHeight = liveCoordinates[Z_AXIS];
				}

				// Check if we've finished the first layer
				if (liveCoordinates[Z_AXIS] > printingFileInfo.firstLayerHeight + LAYER_HEIGHT_TOLERANCE)
				{
					FirstLayerComplete();
					currentLayer++;

					lastLayerZ = liveCoordinates[Z_AXIS];
					lastLayerChangeTime = GetPrintDuration();
				}
			}
			// Check for following layer changes
			else if (liveCoordinates[Z_AXIS] > lastLayerZ + LAYER_HEIGHT_TOLERANCE)
			{
				LayerComplete();
				currentLayer++;

				// If we know the layer height, compute what the current layer height should be. This is to handle slicers that use a different layer height for support.
				lastLayerZ = (printingFileInfo.layerHeight > 0.0)
								? printingFileInfo.firstLayerHeight + (currentLayer - 1) * printingFileInfo.layerHeight
									: liveCoordinates[Z_AXIS];
				lastLayerChangeTime = GetPrintDuration();
			}
		}
		lastUpdateTime = now;
	}
}

float PrintMonitor::GetWarmUpDuration() const
{
	if (currentLayer > 0)
	{
		return warmUpDuration;
	}
	return heatingUp ? GetPrintDuration() : 0.0;
}

// Notifies this class that a file has been set for printing
void PrintMonitor::StartingPrint(const char* filename)
{
	printingFileParsed = platform.GetMassStorage()->GetFileInfo(platform.GetGCodeDir(), filename, printingFileInfo, false);
	filenameBeingPrinted.copy(filename);
}

// Tell this class that the file set for printing is now actually processed
void PrintMonitor::StartedPrint()
{
	isPrinting = true;
	printStartTime = millis64();
}

// This is called as soon as the heaters are at temperature and the actual print has started
void PrintMonitor::WarmUpComplete()
{
	heatingUp = false;
	warmUpDuration = GetPrintDuration();
}

// Called when the first layer has been finished
void PrintMonitor::FirstLayerComplete()
{
	firstLayerFilament = gCodes.GetTotalRawExtrusion();
	firstLayerDuration = GetPrintDuration() - warmUpDuration;
	firstLayerProgress = gCodes.FractionOfFilePrinted();

	// Update layer-based estimation time (if the object and layer heights are known)
	// This won't be very accurate, but at least something can be sent the web interface and to PanelDue
	if (printingFileInfo.layerHeight > 0.0 && printingFileInfo.objectHeight > printingFileInfo.layerHeight)
	{
		unsigned int layersToPrint = lrintf((printingFileInfo.objectHeight - printingFileInfo.firstLayerHeight) / printingFileInfo.layerHeight) + 1;
		layerEstimatedTimeLeft = firstLayerDuration * FIRST_LAYER_SPEED_FACTOR * (layersToPrint - 1);
	}
}

// This is called whenever a layer greater than 2 has been finished
void PrintMonitor::LayerComplete()
{
	// Record a new set of layer, filament and file stats
	const float extrRawTotal = gCodes.GetTotalRawExtrusion();
	if (numLayerSamples < MAX_LAYER_SAMPLES)
	{
		if (numLayerSamples == 0)
		{
			filamentUsagePerLayer[numLayerSamples] = extrRawTotal - firstLayerFilament;
			layerDurations[numLayerSamples] = GetPrintDuration() - warmUpDuration;
		}
		else
		{
			filamentUsagePerLayer[numLayerSamples] = extrRawTotal - lastLayerFilament;
			layerDurations[numLayerSamples] = GetPrintDuration() - lastLayerChangeTime;
		}
		fileProgressPerLayer[numLayerSamples] = gCodes.FractionOfFilePrinted();
		numLayerSamples++;
	}
	else
	{
		for(size_t i = 1; i < MAX_LAYER_SAMPLES; i++)
		{
			layerDurations[i - 1] = layerDurations[i];
			filamentUsagePerLayer[i - 1] = filamentUsagePerLayer[i];
			fileProgressPerLayer[i - 1] = fileProgressPerLayer[i];
		}

		layerDurations[MAX_LAYER_SAMPLES - 1] = GetPrintDuration() - lastLayerChangeTime;
		filamentUsagePerLayer[MAX_LAYER_SAMPLES - 1] = extrRawTotal - lastLayerFilament;
		fileProgressPerLayer[MAX_LAYER_SAMPLES - 1] = gCodes.FractionOfFilePrinted();
	}
	lastLayerFilament = extrRawTotal;

	// Update layer-based estimation time (if the object and layer heights are known)
	if (printingFileInfo.layerHeight > 0.0 && printingFileInfo.objectHeight > printingFileInfo.layerHeight)
	{
		// Calculate the average layer time and include the first layer if possible
		float avgLayerTime = (numLayerSamples < MAX_LAYER_SAMPLES)
								? firstLayerDuration * FIRST_LAYER_SPEED_FACTOR
								: 0.0;
		for(size_t layer = 0; layer < numLayerSamples; layer++)
		{
			avgLayerTime += layerDurations[layer];
		}
		avgLayerTime /= (numLayerSamples < MAX_LAYER_SAMPLES) ? numLayerSamples + 1 : numLayerSamples;

		// Estimate the layer-based time left
		const unsigned int totalLayers = lrintf((printingFileInfo.objectHeight - printingFileInfo.firstLayerHeight) / printingFileInfo.layerHeight) + 1;
		if (currentLayer < totalLayers)
		{
			// Current layer is within reasonable boundaries, so an estimation can be made
			layerEstimatedTimeLeft = avgLayerTime * (totalLayers - currentLayer);
		}
		else
		{
			// Current layer is higher than the maximum number of layers. Assume the print has almost finished
			layerEstimatedTimeLeft = 0.1;
		}
	}
}

void PrintMonitor::StoppedPrint()
{
	isPrinting = heatingUp = printingFileParsed = false;
	currentLayer = numLayerSamples = 0;
	pauseStartTime = totalPauseTime = 0;
	firstLayerDuration = firstLayerFilament = firstLayerProgress = 0.0;
	layerEstimatedTimeLeft = printStartTime = warmUpDuration = 0.0;
	lastLayerChangeTime = lastLayerFilament = lastLayerZ = 0.0;
}

// Estimate the print time left in seconds on a preset estimation method
float PrintMonitor::EstimateTimeLeft(PrintEstimationMethod method) const
{
	// We can't provide an estimation if we don't have any information about the file
	if (!printingFileParsed)
	{
		return 0.0;
	}

	// How long have we been printing continuously?
	float realPrintDuration = GetPrintDuration() - warmUpDuration;

	switch (method)
	{
		case fileBased:
		{
			// Can we provide an estimation at all?
			const float fractionPrinted = gCodes.FractionOfFilePrinted();
			if (fractionPrinted < ESTIMATION_MIN_FILE_USAGE || heatingUp)
			{
				// No, we haven't printed enough of the file yet. We can't provide an estimation at this moment
				return 0.0;
			}
			if (fractionPrinted == 1.0)
			{
				// No, but the file has been processed entirely. It won't take long until the print finishes
				return 0.1;
			}

			// See how long it takes per progress
			float duration, fractionPrintedInLayers;
			if (numLayerSamples == 0)
			{
				duration = firstLayerDuration;
				fractionPrintedInLayers = firstLayerProgress;
			}
			else if (numLayerSamples == 1)
			{
				duration = layerDurations[0];
				fractionPrintedInLayers = fileProgressPerLayer[0] - firstLayerProgress;
			}
			else if (numLayerSamples > 1)
			{
				duration = 0.0;
				for(size_t sample = 1; sample < numLayerSamples; sample++)
				{
					duration += layerDurations[sample];
				}
				fractionPrintedInLayers = fileProgressPerLayer[numLayerSamples - 1] - fileProgressPerLayer[0];
			}

			// Can we use these values?
			if (fractionPrintedInLayers < ESTIMATION_MIN_FILE_USAGE)
			{
				// No - only provide a rough estimation
				return max<float>(realPrintDuration * (1.0 / fractionPrinted) - realPrintDuration, 0.1);
			}

			// Yes...
			return max<float>(duration * (1.0 - fractionPrinted) / fractionPrintedInLayers, 0.1);
		}

		case filamentBased:
		{
			// Need some file information, otherwise this method won't work
			if (currentLayer == 0 || printingFileInfo.numFilaments == 0
#if SUPPORT_ROLAND
					|| reprap.GetRoland()->Active()
#endif
				)
			{
				return 0.0;
			}

			// Sum up the filament usage and the filament needed
			float totalFilamentNeeded = 0.0;
			const float extrRawTotal = gCodes.GetTotalRawExtrusion();
			for (size_t extruder = 0; extruder < DRIVES - reprap.GetGCodes().GetTotalAxes(); extruder++)
			{
				totalFilamentNeeded += printingFileInfo.filamentNeeded[extruder];
			}

			// If we have a reasonable amount of filament extruded, calculate estimated times left
			if (totalFilamentNeeded > 0.0 && extrRawTotal > totalFilamentNeeded * ESTIMATION_MIN_FILAMENT_USAGE)
			{
				// Do we have more total filament extruded than reported by the file
				if (extrRawTotal >= totalFilamentNeeded)
				{
					// Yes - assume the print has almost finished
					return 0.1;
				}

				// Get filament usage per layer
				float filamentRate = 0.0;
				if (numLayerSamples > 0)
				{
					for(size_t i = 0; i < numLayerSamples; i++)
					{
						filamentRate += filamentUsagePerLayer[i] / layerDurations[i];
					}
					filamentRate /= numLayerSamples;
				}
				else if (firstLayerDuration > 0.0)
				{
					filamentRate = firstLayerFilament / firstLayerDuration;
				}

				// Can we provide a good estimation?
				if (filamentRate == 0.0)
				{
					// No - calculate time left based on the filament we have extruded so far
					return realPrintDuration * (totalFilamentNeeded - extrRawTotal) / extrRawTotal;
				}

				return (totalFilamentNeeded - extrRawTotal) / filamentRate;
			}
			break;
		}

		case layerBased:
			// Layer-based estimations are made after each layer change, only reflect this value
			if (layerEstimatedTimeLeft > 0.0)
			{
				float timeLeft = layerEstimatedTimeLeft - (GetPrintDuration() - lastLayerChangeTime);
				return (timeLeft > 0.0) ? timeLeft : 0.1;
			}
			break;
	}

	return 0.0;
}

// This returns the amount of time the machine has printed without interruptions (i.e. pauses)
float PrintMonitor::GetPrintDuration() const
{
	if (!isPrinting)
	{
		// Can't provide a valid print duration if we don't know when it started
		return 0.0;
	}

	const uint64_t printDuration = ((pauseStartTime != 0) ? pauseStartTime : millis64()) - printStartTime - totalPauseTime;
	return (float)printDuration * 0.001;
}

// vim: ts=4:sw=4