Improve filament sensor PCB upgrade logic

Firmware/Marlin_main.cpp

@@ -9679,42 +9679,94 @@ static void handleSafetyTimer()
 #endif //SAFETYTIMER
 
 #ifdef IR_SENSOR_ANALOG
-#define FS_CHECK_COUNT 16
-/// Switching mechanism of the fsensor type.
-/// Called from 2 spots which have a very similar behavior
-/// 1: ClFsensorPCB::_Old -> ClFsensorPCB::_Rev04 and print _i("FS v0.4 or newer")
-/// 2: ClFsensorPCB::_Rev04 -> oFsensorPCB=ClFsensorPCB::_Old and print _i("FS v0.3 or older")
-void manage_inactivity_IR_ANALOG_Check(uint16_t &nFSCheckCount, ClFsensorPCB isVersion, ClFsensorPCB switchTo, const char *statusLineTxt_P) {
-    bool bTemp = (!CHECK_ALL_HEATERS);
-    bTemp = bTemp && (menu_menu == lcd_status_screen);
-    bTemp = bTemp && ((oFsensorPCB == isVersion) || (oFsensorPCB == ClFsensorPCB::_Undef));
-    bTemp = bTemp && fsensor_enabled;
-    if (bTemp) {
-        nFSCheckCount++;
-        if (nFSCheckCount > FS_CHECK_COUNT) {
-            nFSCheckCount = 0; // not necessary
-            oFsensorPCB = switchTo;
+void manage_inactivity_IR_ANALOG_CheckPCB()
+{
+    static uint16_t minVolt = Voltage2Raw(6.F), maxVolt = 0;
+    static ClFsensorPCB nFsensorPCB = oFsensorPCB;
+    static uint16_t nFSCheckCount = FS_CHECK_COUNT;
+
+    // only attempt detection when cold and idling in the status screen
+    if (!fsensor_enabled || CHECK_ALL_HEATERS || menu_menu != lcd_status_screen)
+        return;
+
+    // detect min-max, some long term sliding window for filtration may be added
+    // avoiding floating point operations, thus computing in raw
+    if( current_voltage_raw_IR > maxVolt )maxVolt = current_voltage_raw_IR;
+    if( current_voltage_raw_IR < minVolt )minVolt = current_voltage_raw_IR;
+
+#if 0 // Start: IR Sensor debug info
+    { // debug print
+        static uint16_t lastVolt = ~0U;
+        if( current_voltage_raw_IR != lastVolt ){
+            printf_P(PSTR("fs volt=%4.2fV (min=%4.2f max=%4.2f)\n"), Raw2Voltage(current_voltage_raw_IR), Raw2Voltage(minVolt), Raw2Voltage(maxVolt) );
+            lastVolt = current_voltage_raw_IR;
+        }
+    }
+#endif // End: IR Sensor debug info
+
+    //! The trouble is, I can hold the filament in the hole in such a way, that it creates the exact voltage
+    //! to be detected as the new fsensor
+    //! We can either fake it by extending the detection window to a looooong time
+    //! or do some other countermeasures
+    ClFsensorPCB tempFsensorPCB;
+    const char *statusLineTxt_P;
+
+    //! what we want to detect:
+    //! if minvolt gets below ~0.3V, it means there is an old fsensor
+    //! if maxvolt gets above 4.6V, it means we either have an old fsensor or broken cables/fsensor
+    //! So I'm waiting for a situation, when minVolt gets to range <0, 1.5> and maxVolt gets into range <3.0, 5>
+    //! If and only if minVolt is in range <0.3, 1.5> and maxVolt is in range <3.0, 4.6>, I'm considering a situation with the new fsensor
+    if( minVolt >= IRsensor_Ldiode_TRESHOLD && minVolt <= IRsensor_Lmax_TRESHOLD
+        && maxVolt >= IRsensor_Hmin_TRESHOLD && maxVolt <= IRsensor_Hopen_TRESHOLD
+        ){
+        tempFsensorPCB = ClFsensorPCB::_Rev04;
+        statusLineTxt_P = _i("FS v0.4 or newer"); ////MSG_FS_V_04_OR_NEWER c=18
+    }
+    //! If and only if minVolt is in range <0.0, 0.3> and maxVolt is in range  <4.6, 5.0V>, I'm considering a situation with the old fsensor
+    //! Note, we are not relying on one voltage here - getting just +5V can mean an old fsensor or a broken new sensor - that's why
+    //! we need to have both voltages detected correctly to allow switching back to the old fsensor.
+    else if( minVolt < IRsensor_Ldiode_TRESHOLD
+             && maxVolt > IRsensor_Hopen_TRESHOLD && maxVolt <= IRsensor_VMax_TRESHOLD
+             ){
+        tempFsensorPCB = ClFsensorPCB::_Old;
+        statusLineTxt_P = _i("FS v0.3 or older"); ////MSG_FS_V_03_OR_OLDER c=18
+    }
+    //! Ambiguous range
+    else
+    {
+        tempFsensorPCB = ClFsensorPCB::_Undef;
+    }
+
+    if (tempFsensorPCB != ClFsensorPCB::_Undef)
+    {
+        --oFSCheckCount;
+
+        if (tempFsensorPCB != nFsensorPCB)
+        {
+            // latest detection changed, reset internal counters
+            nFsensorPCB = tempFsensorPCB;
+            nFSCheckCount = FS_CHECK_COUNT;
+        }
+        else if(!--nFSCheckCount)
+        {
+            // consistent PCB match, set detected sensor type and stop attempts
+            oFSCheckCount = 0;
+            oFsensorPCB = tempFsensorPCB;
             eeprom_update_byte((uint8_t *)EEPROM_FSENSOR_PCB, (uint8_t)oFsensorPCB);
             printf_IRSensorAnalogBoardChange();
             lcd_setstatuspgm(statusLineTxt_P);
         }
-    } else {
-        nFSCheckCount = 0;
     }
 }
 #endif
 
 void manage_inactivity(bool ignore_stepper_queue/*=false*/) //default argument set in Marlin.h
 {
 #ifdef FILAMENT_SENSOR
-bool bInhibitFlag = false;
-#ifdef IR_SENSOR_ANALOG
-static uint16_t nFSCheckCount=0;
-#endif // IR_SENSOR_ANALOG
+    bool bInhibitFlag = false;
 
 	if (mmu_enabled == false)
 	{
-//-//		if (mcode_in_progress != 600) //M600 not in progress
 		if (!PRINTER_ACTIVE) bInhibitFlag=(menu_menu==lcd_menu_show_sensors_state); //Block Filament sensor actions if PRINTER is not active and Support::SensorInfo menu active
 #ifdef IR_SENSOR_ANALOG
 		bInhibitFlag=bInhibitFlag||bMenuFSDetect; // Block Filament sensor actions if Settings::HWsetup::FSdetect menu active
@@ -9723,80 +9775,33 @@ static uint16_t nFSCheckCount=0;
 		{
 			if (!moves_planned() && !IS_SD_PRINTING && !is_usb_printing && (lcd_commands_type != LcdCommands::Layer1Cal) && ! eeprom_read_byte((uint8_t*)EEPROM_WIZARD_ACTIVE))
 			{
+                // idling: housekeeping and autoload checks
 #ifdef IR_SENSOR_ANALOG
-				static uint16_t minVolt = Voltage2Raw(6.F), maxVolt = 0;
-				// detect min-max, some long term sliding window for filtration may be added
-				// avoiding floating point operations, thus computing in raw
-				if( current_voltage_raw_IR > maxVolt )maxVolt = current_voltage_raw_IR;
-				if( current_voltage_raw_IR < minVolt )minVolt = current_voltage_raw_IR;
-
-#if 0 // Start: IR Sensor debug info
-				{ // debug print
-					static uint16_t lastVolt = ~0U;
-					if( current_voltage_raw_IR != lastVolt ){
-						printf_P(PSTR("fs volt=%4.2fV (min=%4.2f max=%4.2f)\n"), Raw2Voltage(current_voltage_raw_IR), Raw2Voltage(minVolt), Raw2Voltage(maxVolt) );
-						lastVolt = current_voltage_raw_IR;
-					}
-				}
-#endif // End: IR Sensor debug info
-				//! The trouble is, I can hold the filament in the hole in such a way, that it creates the exact voltage
-				//! to be detected as the new fsensor
-				//! We can either fake it by extending the detection window to a looooong time
-				//! or do some other countermeasures
-
-				//! what we want to detect:
-				//! if minvolt gets below ~0.3V, it means there is an old fsensor
-				//! if maxvolt gets above 4.6V, it means we either have an old fsensor or broken cables/fsensor
-				//! So I'm waiting for a situation, when minVolt gets to range <0, 1.5> and maxVolt gets into range <3.0, 5>
-				//! If and only if minVolt is in range <0.3, 1.5> and maxVolt is in range <3.0, 4.6>, I'm considering a situation with the new fsensor
-				if( minVolt >= IRsensor_Ldiode_TRESHOLD && minVolt <= IRsensor_Lmax_TRESHOLD 
-				 && maxVolt >= IRsensor_Hmin_TRESHOLD && maxVolt <= IRsensor_Hopen_TRESHOLD
-				){
-					manage_inactivity_IR_ANALOG_Check(nFSCheckCount, ClFsensorPCB::_Old, ClFsensorPCB::_Rev04, _i("FS v0.4 or newer") ); ////MSG_FS_V_04_OR_NEWER c=18
-				} 
-				//! If and only if minVolt is in range <0.0, 0.3> and maxVolt is in range  <4.6, 5.0V>, I'm considering a situation with the old fsensor
-				//! Note, we are not relying on one voltage here - getting just +5V can mean an old fsensor or a broken new sensor - that's why
-				//! we need to have both voltages detected correctly to allow switching back to the old fsensor.
-				else if( minVolt < IRsensor_Ldiode_TRESHOLD 
-				 && maxVolt > IRsensor_Hopen_TRESHOLD && maxVolt <= IRsensor_VMax_TRESHOLD
-				){
-					manage_inactivity_IR_ANALOG_Check(nFSCheckCount, ClFsensorPCB::_Rev04, oFsensorPCB=ClFsensorPCB::_Old, _i("FS v0.3 or older")); ////MSG_FS_V_03_OR_OLDER c=18
-				}
+                if (oFSCheckCount)
+                {
+                    // Attempt to detect an upgrade of the filament sensor PCB
+                    manage_inactivity_IR_ANALOG_CheckPCB();
+                }
 #endif // IR_SENSOR_ANALOG
 				if (fsensor_check_autoload())
 				{
 #ifdef PAT9125
 					fsensor_autoload_check_stop();
 #endif //PAT9125
-//-//					if (degHotend0() > EXTRUDE_MINTEMP)
-if(0)
-					{
-						Sound_MakeCustom(50,1000,false);
-						loading_flag = true;
-						enquecommand_front_P((PSTR("M701")));
-					}
-					else
-					{
-/*
-						lcd_update_enable(false);
-						show_preheat_nozzle_warning();
-						lcd_update_enable(true);
-*/
-						eFilamentAction=FilamentAction::AutoLoad;
-						bFilamentFirstRun=false;
-						if(target_temperature[0]>=EXTRUDE_MINTEMP){
-							bFilamentPreheatState=true;
-//							mFilamentItem(target_temperature[0],target_temperature_bed);
-							menu_submenu(mFilamentItemForce);
-						} else {
-							menu_submenu(lcd_generic_preheat_menu);
-							lcd_timeoutToStatus.start();
-						}
-					}
+                    eFilamentAction=FilamentAction::AutoLoad;
+                    bFilamentFirstRun=false;
+                    if(target_temperature[0]>=EXTRUDE_MINTEMP){
+                        bFilamentPreheatState=true;
+                        menu_submenu(mFilamentItemForce);
+                    } else {
+                        menu_submenu(lcd_generic_preheat_menu);
+                        lcd_timeoutToStatus.start();
+                    }
 				}
 			}
 			else
 			{
+                // printing: runout detection
 #ifdef PAT9125
 				fsensor_autoload_check_stop();
 #endif //PAT9125

Firmware/fsensor.cpp

@@ -123,6 +123,7 @@ uint16_t fsensor_oq_sh_sum;
 #ifdef IR_SENSOR_ANALOG
 ClFsensorPCB oFsensorPCB;
 ClFsensorActionNA oFsensorActionNA;
+uint16_t oFSCheckCount = FS_CHECK_COUNT * 3;
 bool bIRsensorStateFlag=false;
 unsigned long nIRsensorLastTime;
 #endif //IR_SENSOR_ANALOG
@@ -208,6 +209,10 @@ void fsensor_init(void)
 	oFsensorPCB = (ClFsensorPCB)eeprom_read_byte((uint8_t*)EEPROM_FSENSOR_PCB);
 	oFsensorActionNA = (ClFsensorActionNA)eeprom_read_byte((uint8_t*)EEPROM_FSENSOR_ACTION_NA);
 
+    // disable checking for PCB updates if already at the newest version
+    if(oFsensorPCB == ClFsensorPCB::_Newest)
+        oFSCheckCount = 0;
+
 	// If the fsensor is not responding even at the start of the printer,
 	// set this flag accordingly to show N/A in Settings->Filament sensor.
 	// This is even valid for both fsensor board revisions (0.3 or older and 0.4).

Firmware/fsensor.h

@@ -83,15 +83,18 @@ extern uint8_t fsensor_log;
 //! @}
 #endif //PAT9125
 
-#define VOLT_DIV_REF 5
-
 #ifdef IR_SENSOR_ANALOG
 #define IR_SENSOR_STEADY 10                       // [ms]
 
+// number of required consistent consecutive filament sensor check attempts
+#define FS_CHECK_COUNT 16
+// number of remaining filament sensor checks to be done
+extern uint16_t oFSCheckCount;
+
 enum class ClFsensorPCB:uint_least8_t
 {
     _Old=0,
-    _Rev04=1,
+    _Rev04=1, _Newest=1,
     _Undef=EEPROM_EMPTY_VALUE
 };
 
@@ -107,12 +110,8 @@ extern ClFsensorActionNA oFsensorActionNA;
 extern const char* FsensorIRVersionText();
 
 extern bool fsensor_IR_check();
-constexpr uint16_t Voltage2Raw(float V){
-	return ( V * 1023 * OVERSAMPLENR / VOLT_DIV_REF ) + 0.5F;
-}
-constexpr float Raw2Voltage(uint16_t raw){
-	return VOLT_DIV_REF*(raw / (1023.F * OVERSAMPLENR) );
-}
+
+#include "temperature.h"
 constexpr uint16_t IRsensor_Ldiode_TRESHOLD = Voltage2Raw(0.3F); // ~0.3V, raw value=982
 constexpr uint16_t IRsensor_Lmax_TRESHOLD = Voltage2Raw(1.5F); // ~1.5V (0.3*Vcc), raw value=4910
 constexpr uint16_t IRsensor_Hmin_TRESHOLD = Voltage2Raw(3.0F); // ~3.0V (0.6*Vcc), raw value=9821

Firmware/temperature.h

@@ -42,6 +42,15 @@
 
 #endif //SYSTEM_TIMER_2
 
+// voltage conversion functions
+#define VOLT_DIV_REF 5
+
+constexpr uint16_t Voltage2Raw(float V){
+	return ( V * 1023 * OVERSAMPLENR / VOLT_DIV_REF ) + 0.5F;
+}
+constexpr float Raw2Voltage(uint16_t raw){
+	return VOLT_DIV_REF*(raw / (1023.F * OVERSAMPLENR) );
+}
 
 // public functions
 void tp_init();  //initialize the heating

Firmware/ultralcd.cpp

@@ -7301,7 +7301,7 @@ void lcd_belttest()
 #ifdef IR_SENSOR_ANALOG
 // called also from marlin_main.cpp
 void printf_IRSensorAnalogBoardChange(){
-    printf_P(PSTR("Filament sensor board change detected: revision%S\n"), FsensorIRVersionText());
+    printf_P(PSTR("Filament sensor board change detected: revision %S\n"), FsensorIRVersionText());
 }
 
 static bool lcd_selftest_IRsensor(bool bStandalone)
@@ -7327,6 +7327,7 @@ static bool lcd_selftest_IRsensor(bool bStandalone)
     }
     if((bPCBrev04 ? 1 : 0) != (uint8_t)oFsensorPCB){        // safer then "(uint8_t)bPCBrev04"
         oFsensorPCB=bPCBrev04 ? ClFsensorPCB::_Rev04 : ClFsensorPCB::_Old;
+        oFSCheckCount = 0;
         printf_IRSensorAnalogBoardChange();
         eeprom_update_byte((uint8_t*)EEPROM_FSENSOR_PCB,(uint8_t)oFsensorPCB);
     }