Separate endstop and motion sensor thresholds in filament runout detection

Marlin/Configuration.h

@@ -2037,8 +2037,11 @@
     //#define FILAMENT_MOTION_SENSOR
 
     #if ENABLED(FILAMENT_MOTION_SENSOR)
-      //#define FILAMENT_SWITCH_AND_MOTION
+      //#define FILAMENT_SWITCH_AND_MOTION      // Define separate pins below to sense motion
       #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+
+        #define FILAMENT_MOTION_DISTANCE_MM 3.0 // (mm) Missing distance required to trigger runout
+
         #define NUM_MOTION_SENSORS   1          // Number of sensors, up to one per extruder. Define a FIL_MOTION#_PIN for each.
         //#define FIL_MOTION1_PIN    -1
 
@@ -2074,7 +2077,7 @@
         //#define FIL_MOTION8_STATE LOW
         //#define FIL_MOTION8_PULLUP
         //#define FIL_MOTION8_PULLDOWN
-      #endif
+      #endif // FILAMENT_SWITCH_AND_MOTION
     #endif // FILAMENT_MOTION_SENSOR
   #endif // FILAMENT_RUNOUT_DISTANCE_MM
 #endif // FILAMENT_RUNOUT_SENSOR

Marlin/src/feature/runout.cpp

@@ -33,7 +33,7 @@
 FilamentMonitor runout;
 
 bool FilamentMonitorBase::enabled = true,
-     FilamentMonitorBase::filament_ran_out;  // = false
+     FilamentMonitorBase::filament_ran_out; // = false
 
 #if ENABLED(HOST_ACTION_COMMANDS)
   bool FilamentMonitorBase::host_handling; // = false
@@ -51,6 +51,11 @@ bool FilamentMonitorBase::enabled = true,
   #if ENABLED(FILAMENT_MOTION_SENSOR)
     uint8_t FilamentSensorEncoder::motion_detected;
   #endif
+
+  #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+    bool RunoutResponseDelayed::ignore_motion = false;
+    constexpr float RunoutResponseDelayed::motion_distance_mm;
+  #endif
 #else
   int8_t RunoutResponseDebounced::runout_count[NUM_RUNOUT_SENSORS]; // = 0
 #endif
@@ -72,6 +77,8 @@ bool FilamentMonitorBase::enabled = true,
 
 void event_filament_runout(const uint8_t extruder) {
 
+  runout.init_for_restart(false); // Reset and disable
+
   if (did_pause_print) return;  // Action already in progress. Purge triggered repeated runout.
 
   #if ENABLED(TOOLCHANGE_MIGRATION_FEATURE)

Marlin/src/feature/runout.h

@@ -46,8 +46,10 @@
 
 #if ENABLED(FILAMENT_MOTION_SENSOR)
   #define HAS_FILAMENT_MOTION 1
-#endif
-#if DISABLED(FILAMENT_MOTION_SENSOR) || ENABLED(FILAMENT_SWITCH_AND_MOTION)
+  #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+    #define HAS_FILAMENT_SWITCH 1
+  #endif
+#else
   #define HAS_FILAMENT_SWITCH 1
 #endif
 
@@ -129,6 +131,7 @@ class TFilamentMonitor : public FilamentMonitorBase {
 
     // Handle a block completion. RunoutResponseDelayed uses this to
     // add up the length of filament moved while the filament is out.
+    // Called from ISR context!
     static void block_completed(const block_t * const b) {
       if (enabled) {
         response.block_completed(b);
@@ -171,6 +174,12 @@ class TFilamentMonitor : public FilamentMonitorBase {
         }
       }
     }
+
+    // Reset after a filament runout or upon resuming a job
+    static void init_for_restart(const bool onoff=true) {
+      response.init_for_restart(onoff);
+    }
+
 };
 
 /*************************** FILAMENT PRESENCE SENSORS ***************************/
@@ -267,6 +276,7 @@ class FilamentSensorBase {
       }
 
     public:
+      // Called from ISR context to indicate a block was completed
       static void block_completed(const block_t * const b) {
         // If the sensor wheel has moved since the last call to
         // this method reset the runout counter for the extruder.
@@ -303,6 +313,7 @@ class FilamentSensorBase {
       }
 
     public:
+      // Called from ISR context to indicate a block was completed
       static void block_completed(const block_t * const) {}
 
       static void run() {
@@ -332,6 +343,7 @@ class FilamentSensorBase {
       TERN_(HAS_FILAMENT_SWITCH, static FilamentSensorSwitch switch_sensor);
 
     public:
+      // Called from ISR context to indicate a block was completed
       static void block_completed(const block_t * const b) {
         TERN_(HAS_FILAMENT_MOTION, encoder_sensor.block_completed(b));
         TERN_(HAS_FILAMENT_SWITCH, switch_sensor.block_completed(b));
@@ -362,10 +374,17 @@ class FilamentSensorBase {
   class RunoutResponseDelayed {
     private:
       static countdown_t mm_countdown;
+      static bool ignore_motion;  // Flag to ignore the encoder
 
     public:
       static float runout_distance_mm;
 
+      #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+        static constexpr float motion_distance_mm = FILAMENT_MOTION_DISTANCE_MM;
+      #endif
+
+      static void set_ignore_motion(const bool ignore=true) { ignore_motion = ignore; }
+
       static void reset() {
         for (uint8_t i = 0; i < NUM_RUNOUT_SENSORS; ++i) filament_present(i);
         #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
@@ -377,24 +396,27 @@ class FilamentSensorBase {
         #if ENABLED(FILAMENT_RUNOUT_SENSOR_DEBUG)
           static millis_t t = 0;
           const millis_t ms = millis();
-          if (ELAPSED(ms, t)) {
-            t = millis() + 1000UL;
-            for (uint8_t i = 0; i < NUM_RUNOUT_SENSORS; ++i)
-              SERIAL_ECHO(i ? F(", ") : F("Runout remaining mm: "), mm_countdown.runout[i]);
-            #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
-              for (uint8_t i = 0; i < NUM_MOTION_SENSORS; ++i)
-                SERIAL_ECHO(i ? F(", ") : F("Motion remaining mm: "), mm_countdown.motion[i]);
-            #endif
-            SERIAL_EOL();
-          }
+          if (PENDING(ms, t)) return;
+          t = ms + 1000UL;
+          for (uint8_t i = 0; i < NUM_RUNOUT_SENSORS; ++i)
+            SERIAL_ECHO(i ? F(", ") : F("Runout remaining mm: "), mm_countdown.runout[i]);
+          #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+            for (uint8_t i = 0; i < NUM_MOTION_SENSORS; ++i)
+              SERIAL_ECHO(i ? F(", ") : F("Motion remaining mm: "), mm_countdown.motion[i]);
+          #endif
+          SERIAL_EOL();
         #endif
       }
 
+      // Get runout status for all presence sensors and motion sensors
       static runout_flags_t has_run_out() {
         runout_flags_t runout_flags{0};
+        // Runout based on filament presence
         for (uint8_t i = 0; i < NUM_RUNOUT_SENSORS; ++i) if (mm_countdown.runout[i] < 0) runout_flags.set(i);
+        // Runout based on filament motion
         #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
-          for (uint8_t i = 0; i < NUM_MOTION_SENSORS; ++i) if (mm_countdown.motion[i] < 0) runout_flags.set(i);
+          if (!ignore_motion)
+            for (uint8_t i = 0; i < NUM_MOTION_SENSORS; ++i) if (mm_countdown.motion[i] < 0) runout_flags.set(i);
         #endif
         return runout_flags;
       }
@@ -419,38 +441,51 @@ class FilamentSensorBase {
       #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
         static void filament_motion_present(const uint8_t extruder) {
           // Same logic as filament_present
-          if (mm_countdown.motion[extruder] < runout_distance_mm || did_pause_print) {
-            mm_countdown.motion[extruder] = runout_distance_mm;
+          if (mm_countdown.motion[extruder] < motion_distance_mm || did_pause_print) {
+            mm_countdown.motion[extruder] = motion_distance_mm;
             mm_countdown.motion_reset.clear(extruder);
           }
           else
             mm_countdown.motion_reset.set(extruder);
         }
       #endif
 
+      // Called from ISR context to indicate a block was completed
       static void block_completed(const block_t * const b) {
-        const int32_t esteps = b->steps.e;
-        if (!esteps) return;
-
         // No calculation unless paused or printing
         if (!should_monitor_runout()) return;
 
+        // Only extrusion moves are examined
+        const int32_t esteps = b->steps.e;
+        if (!esteps) return;
+
         // No need to ignore retract/unretract movement since they complement each other
         const uint8_t e = b->extruder;
         const float mm = (b->direction_bits.e ? esteps : -esteps) * planner.mm_per_step[E_AXIS_N(e)];
 
+        // Apply E distance to runout countdown, reset if flagged
         if (e < NUM_RUNOUT_SENSORS) {
           mm_countdown.runout[e] -= mm;
           if (mm_countdown.runout_reset[e]) filament_present(e);          // Reset pending. Try to reset.
         }
 
+        // Apply E distance to motion countdown, reset if flagged
         #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
-          if (e < NUM_MOTION_SENSORS) {
+          if (!ignore_motion && e < NUM_MOTION_SENSORS) {
             mm_countdown.motion[e] -= mm;
             if (mm_countdown.motion_reset[e]) filament_motion_present(e); // Reset pending. Try to reset.
           }
         #endif
       }
+
+      // Reset after a filament runout or upon resuming a job
+      static void init_for_restart(const bool onoff=true) {
+        UNUSED(onoff);
+        #if ENABLED(FILAMENT_SWITCH_AND_MOTION)
+          reset();
+          set_ignore_motion(!onoff);
+        #endif
+      }
   };
 
 #else // !HAS_FILAMENT_RUNOUT_DISTANCE
@@ -478,11 +513,15 @@ class FilamentSensorBase {
         return runout_flags;
       }
 
+      // Called from ISR context to indicate a block was completed
       static void block_completed(const block_t * const) { }
 
       static void filament_present(const uint8_t extruder) {
         runout_count[extruder] = runout_threshold;
       }
+
+      // Reset after a filament runout or upon resuming a job
+      static void init_for_restart(const bool=true) { reset(); }
   };
 
 #endif // !HAS_FILAMENT_RUNOUT_DISTANCE