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Support dual x-carriage printers
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Dual x-carriage designs offer some substantial improvements for dual
extruder printing.
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@buildrob
buildrob committed Jul 17, 2013
1 parent 5ab872d commit d7390e1
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Showing 5 changed files with 242 additions and 25 deletions.
30 changes: 30 additions & 0 deletions Marlin/Configuration_adv.h
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Original file line number Diff line number Diff line change
Expand Up @@ -146,6 +146,36 @@
#define EXTRUDERS 1
#endif

// Enable this for dual x-carriage printers.
// A dual x-carriage design has the advantage that the inactive extruder can be parked which
// prevents hot-end ooze contaminating the print. It also reduces the weight of each x-carriage
// allowing faster printing speeds.
#define DUAL_X_CARRIAGE
#ifdef DUAL_X_CARRIAGE
// Configuration for second X-carriage
// Note: the first x-carriage is defined as the x-carriage which homes to the minimum endstop;
// the second x-carriage always homes to the maximum endstop.
#define X2_MIN_POS 88 // set minimum to ensure second x-carriage doesn't hit the parked first X-carriage
#define X2_MAX_POS 350.45 // set maximum to the distance between toolheads when both heads are homed
#define X2_HOME_DIR 1 // the second X-carriage always homes to the maximum endstop position
#define X2_HOME_POS X2_MAX_POS // default home position is the maximum carriage position
// However: In this mode the EXTRUDER_OFFSET_X value for the second extruder provides a software
// override for X2_HOME_POS. This also allow recalibration of the distance between the two endstops
// without modifying the firmware (through the "M218 T1 X???" command).
// Remember: you should set the second extruder x-offset to 0 in your slicer.

// Pins for second x-carriage stepper driver (defined here to avoid further complicating pins.h)
#define X2_ENABLE_PIN 29
#define X2_STEP_PIN 25
#define X2_DIR_PIN 23

// The following settings control the behaviour of the automatic parking and unparking of inactive extruder
#define TOOLCHANGE_PARK_ZLIFT 0.1 // the distance to raise Z axis when parking an extruder
#define TOOLCHANGE_UNPARK_ZLIFT 1 // the distance to raise Z axis when unparking an extruder
#define TOOLCHANGE_UNPARK_SKIP_TRAVEL_MOVES // disable if slicer natively suports dual x-carriage mode.
// When enabled this avoids unnecessary & inadvertant moves from the last position of old extruder.
#endif // DUAL_X_CARRIAGE

//homing hits the endstop, then retracts by this distance, before it tries to slowly bump again:
#define X_HOME_RETRACT_MM 5
#define Y_HOME_RETRACT_MM 5
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6 changes: 5 additions & 1 deletion Marlin/Marlin.h
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Original file line number Diff line number Diff line change
Expand Up @@ -96,7 +96,11 @@ void process_commands();

void manage_inactivity();

#if defined(X_ENABLE_PIN) && X_ENABLE_PIN > -1
#if defined(DUAL_X_CARRIAGE) && defined(X_ENABLE_PIN) && X_ENABLE_PIN > -1 \
&& defined(X2_ENABLE_PIN) && X2_ENABLE_PIN > -1
#define enable_x() do { WRITE(X_ENABLE_PIN, X_ENABLE_ON); WRITE(X2_ENABLE_PIN, X_ENABLE_ON); } while (0)
#define disable_x() do { WRITE(X_ENABLE_PIN,!X_ENABLE_ON); WRITE(X2_ENABLE_PIN,!X_ENABLE_ON); } while (0)
#elif defined(X_ENABLE_PIN) && X_ENABLE_PIN > -1
#define enable_x() WRITE(X_ENABLE_PIN, X_ENABLE_ON)
#define disable_x() WRITE(X_ENABLE_PIN,!X_ENABLE_ON)
#else
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141 changes: 139 additions & 2 deletions Marlin/Marlin_main.cpp
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Original file line number Diff line number Diff line change
Expand Up @@ -677,7 +677,46 @@ XYZ_CONSTS_FROM_CONFIG(float, max_length, MAX_LENGTH);
XYZ_CONSTS_FROM_CONFIG(float, home_retract_mm, HOME_RETRACT_MM);
XYZ_CONSTS_FROM_CONFIG(signed char, home_dir, HOME_DIR);

#ifdef DUAL_X_CARRIAGE
#if EXTRUDERS == 1 || defined(COREXY) \
|| !defined(X2_ENABLE_PIN) || !defined(X2_STEP_PIN) || !defined(X2_DIR_PIN) \
|| !defined(X2_HOME_POS) || !defined(X2_MIN_POS) || !defined(X2_MAX_POS) \
|| !defined(X_MAX_PIN) || X_MAX_PIN < 0
#error "Missing or invalid definitions for DUAL_X_CARRIAGE mode."
#endif
#if X_HOME_DIR != -1 || X2_HOME_DIR != 1
#error "Please use canonical x-carriage assignment" // the x-carriages are defined by their homing directions
#endif

static float x_home_pos(int extruder) {
if (extruder == 0)
return base_home_pos(X_AXIS) + add_homeing[X_AXIS];
else
// In dual carriage mode the extruder offset provides an override of the
// second X-carriage offset when homed - otherwise X2_HOME_POS is used.
// This allow soft recalibration of the second extruder offset position without firmware reflash
// (through the M218 command).
return (extruder_offset[X_AXIS][1] != 0) ? extruder_offset[X_AXIS][1] : X2_HOME_POS;
}

static int x_home_dir(int extruder) {
return (extruder == 0) ? X_HOME_DIR : X2_HOME_DIR;
}

static bool active_extruder_parked = false;
static float raised_parked_position[NUM_AXIS];
static unsigned long delayed_move_time = 0;
#endif

static void axis_is_at_home(int axis) {
#ifdef DUAL_X_CARRIAGE
if (axis == X_AXIS && active_extruder != 0) {
current_position[X_AXIS] = x_home_pos(active_extruder);
min_pos[X_AXIS] = X2_MIN_POS;
max_pos[X_AXIS] = X2_MAX_POS;
return;
}
#endif
current_position[axis] = base_home_pos(axis) + add_homeing[axis];
min_pos[axis] = base_min_pos(axis) + add_homeing[axis];
max_pos[axis] = base_max_pos(axis) + add_homeing[axis];
Expand All @@ -686,10 +725,16 @@ static void axis_is_at_home(int axis) {
static void homeaxis(int axis) {
#define HOMEAXIS_DO(LETTER) \
((LETTER##_MIN_PIN > -1 && LETTER##_HOME_DIR==-1) || (LETTER##_MAX_PIN > -1 && LETTER##_HOME_DIR==1))

if (axis==X_AXIS ? HOMEAXIS_DO(X) :
axis==Y_AXIS ? HOMEAXIS_DO(Y) :
axis==Z_AXIS ? HOMEAXIS_DO(Z) :
0) {
int axis_home_dir = home_dir(axis);
#ifdef DUAL_X_CARRIAGE
if (axis == X_AXIS)
axis_home_dir = x_home_dir(active_extruder);
#endif

// Engage Servo endstop if enabled
#ifdef SERVO_ENDSTOPS
Expand Down Expand Up @@ -864,8 +909,14 @@ void process_commands()
{
current_position[X_AXIS] = 0;current_position[Y_AXIS] = 0;

#ifdef DUAL_X_CARRIAGE
int x_axis_home_dir = home_dir(X_AXIS);
#else
int x_axis_home_dir = x_home_dir(active_extruder);
#endif

plan_set_position(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS], current_position[E_AXIS]);
destination[X_AXIS] = 1.5 * X_MAX_LENGTH * X_HOME_DIR;destination[Y_AXIS] = 1.5 * Y_MAX_LENGTH * Y_HOME_DIR;
destination[X_AXIS] = 1.5 * max_length(X_AXIS) * x_axis_home_dir;destination[Y_AXIS] = 1.5 * max_length(Y_AXIS) * home_dir(Y_AXIS);
feedrate = homing_feedrate[X_AXIS];
if(homing_feedrate[Y_AXIS]<feedrate)
feedrate =homing_feedrate[Y_AXIS];
Expand All @@ -890,6 +941,14 @@ void process_commands()

if((home_all_axis) || (code_seen(axis_codes[X_AXIS])))
{
#ifdef DUAL_X_CARRIAGE
int tmp_extruder = active_extruder;
active_extruder = !active_extruder;
HOMEAXIS(X);
active_extruder = tmp_extruder;
active_extruder_parked = false;
delayed_move_time = 0;
#endif
HOMEAXIS(X);
}

Expand Down Expand Up @@ -922,7 +981,7 @@ void process_commands()
}
}
plan_set_position(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS], current_position[E_AXIS]);
#endif // DELTA
#endif // else DELTA

#ifdef ENDSTOPS_ONLY_FOR_HOMING
enable_endstops(false);
Expand Down Expand Up @@ -2001,6 +2060,36 @@ void process_commands()
if(tmp_extruder != active_extruder) {
// Save current position to return to after applying extruder offset
memcpy(destination, current_position, sizeof(destination));
#ifdef DUAL_X_CARRIAGE
if (Stopped == false && delayed_move_time == 0 && current_position[X_AXIS] != x_home_pos(active_extruder))
{
// Park old head: 1) raise 2) move to park position 3) lower
plan_buffer_line(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS] + TOOLCHANGE_PARK_ZLIFT,
current_position[E_AXIS], max_feedrate[Z_AXIS], active_extruder);
plan_buffer_line(x_home_pos(active_extruder), current_position[Y_AXIS], current_position[Z_AXIS] + TOOLCHANGE_PARK_ZLIFT,
current_position[E_AXIS], max_feedrate[X_AXIS], active_extruder);
plan_buffer_line(x_home_pos(active_extruder), current_position[Y_AXIS], current_position[Z_AXIS],
current_position[E_AXIS], max_feedrate[Z_AXIS], active_extruder);
st_synchronize();
}

// only apply Y extruder offset in dual x carriage mode (x offset is already used in determining home pos)
current_position[Y_AXIS] = current_position[Y_AXIS] -
extruder_offset[Y_AXIS][active_extruder] +
extruder_offset[Y_AXIS][tmp_extruder];

active_extruder = tmp_extruder;

// Inactive head always starts at its parked position.
axis_is_at_home(X_AXIS);

// record raised toolhead position for use by unpark
memcpy(raised_parked_position, current_position, sizeof(raised_parked_position));
raised_parked_position[Z_AXIS] += TOOLCHANGE_UNPARK_ZLIFT;

active_extruder_parked = true;
delayed_move_time = 0;
#else
// Offset extruder (only by XY)
int i;
for(i = 0; i < 2; i++) {
Expand All @@ -2010,6 +2099,7 @@ void process_commands()
}
// Set the new active extruder and position
active_extruder = tmp_extruder;
#endif //else DUAL_X_CARRIAGE
plan_set_position(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS], current_position[E_AXIS]);
// Move to the old position if 'F' was in the parameters
if(make_move && Stopped == false) {
Expand Down Expand Up @@ -2204,6 +2294,40 @@ void prepare_move()
active_extruder);
}
#else

#if defined(DUAL_X_CARRIAGE)
if (active_extruder_parked)
{
if (current_position[E_AXIS] == destination[E_AXIS])
{
// this is a travel move
#ifdef TOOLCHANGE_UNPARK_SKIP_TRAVEL_MOVES
if (delayed_move_time != 0xFFFFFFFFUL)
{
// skip this move but still update current_position in main so that it can
// be used as starting position before extrusion (but not in planner)
memcpy(current_position, destination, sizeof(current_position));
if (destination[Z_AXIS] > raised_parked_position[Z_AXIS])
raised_parked_position[Z_AXIS] = destination[Z_AXIS];
delayed_move_time = millis();
return;
}
delayed_move_time = 0;
#else
// this will cause the unpark code below to execute the specified lift in moving to the initial (travel move) position.
memcpy(current_position, destination, sizeof(current_position));
#endif
}
// unpark extruder: 1) raise, 2) move into starting XY position, 3) lower
plan_buffer_line(raised_parked_position[X_AXIS], raised_parked_position[Y_AXIS], raised_parked_position[Z_AXIS], current_position[E_AXIS], max_feedrate[Z_AXIS], active_extruder);
plan_buffer_line(current_position[X_AXIS], current_position[Y_AXIS], raised_parked_position[Z_AXIS],
current_position[E_AXIS], min(max_feedrate[X_AXIS],max_feedrate[Y_AXIS]), active_extruder);
plan_buffer_line(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS],
current_position[E_AXIS], max_feedrate[Z_AXIS], active_extruder);
active_extruder_parked = false;
}
#endif //DUAL_X_CARRIAGE

// Do not use feedmultiply for E or Z only moves
if( (current_position[X_AXIS] == destination [X_AXIS]) && (current_position[Y_AXIS] == destination [Y_AXIS])) {
plan_buffer_line(destination[X_AXIS], destination[Y_AXIS], destination[Z_AXIS], destination[E_AXIS], feedrate/60, active_extruder);
Expand Down Expand Up @@ -2254,6 +2378,9 @@ void controllerFan()
|| !READ(E2_ENABLE_PIN)
#endif
#if EXTRUDER > 1
#if defined(X2_ENABLE_PIN) && X2_ENABLE_PIN > -1
|| !READ(X2_ENABLE_PIN)
#endif
|| !READ(E1_ENABLE_PIN)
#endif
|| !READ(E0_ENABLE_PIN)) //If any of the drivers are enabled...
Expand Down Expand Up @@ -2320,6 +2447,16 @@ void manage_inactivity()
WRITE(E0_ENABLE_PIN,oldstatus);
}
#endif
#if defined(DUAL_X_CARRIAGE) && defined(TOOLCHANGE_UNPARK_SKIP_TRAVEL_MOVES)
// handle delayed move timeout
if (delayed_move_time != 0 && (millis() - delayed_move_time) > 1000)
{
// travel moves have been received so enact them
delayed_move_time = 0xFFFFFFFFUL; // force moves to be done
memcpy(destination,current_position,sizeof(destination));
prepare_move();
}
#endif
check_axes_activity();
}

Expand Down
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