⚡️ Improve Sensorless homing/probing for G28, G33 (#21899)

Marlin/src/MarlinCore.cpp

@@ -828,10 +828,8 @@ void idle(bool no_stepper_sleep/*=false*/) {
 
   // Run StallGuard endstop checks
   #if ENABLED(SPI_ENDSTOPS)
-    if (endstops.tmc_spi_homing.any
+    if (endstops.tmc_spi_homing.any && TERN1(IMPROVE_HOMING_RELIABILITY, ELAPSED(millis(), sg_guard_period)))
-      && TERN1(IMPROVE_HOMING_RELIABILITY, ELAPSED(millis(), sg_guard_period))
+      LOOP_L_N(i, 4) if (endstops.tmc_spi_homing_check()) break; // Read SGT 4 times per idle loop
-    ) LOOP_L_N(i, 4) // Read SGT 4 times per idle loop
-        if (endstops.tmc_spi_homing_check()) break;
   #endif
 
   // Handle SD Card insert / remove

Marlin/src/feature/tmc_util.h

@@ -360,13 +360,6 @@ void test_tmc_connection(LOGICAL_AXIS_DECL(const bool, true));
   #if ENABLED(IMPROVE_HOMING_RELIABILITY)
     extern millis_t sg_guard_period;
     constexpr uint16_t default_sg_guard_duration = 400;
-
-    struct motion_state_t {
-      xy_ulong_t acceleration;
-      #if HAS_CLASSIC_JERK
-        xy_float_t jerk_state;
-      #endif
-    };
   #endif
 
   bool tmc_enable_stallguard(TMC2130Stepper &st);

Marlin/src/gcode/calibrate/G28.cpp

@@ -167,12 +167,15 @@
   motion_state_t begin_slow_homing() {
     motion_state_t motion_state{0};
     motion_state.acceleration.set(planner.settings.max_acceleration_mm_per_s2[X_AXIS],
-                                 planner.settings.max_acceleration_mm_per_s2[Y_AXIS]);
+                                 planner.settings.max_acceleration_mm_per_s2[Y_AXIS]
+                                 OPTARG(DELTA, planner.settings.max_acceleration_mm_per_s2[Z_AXIS])
+                               );
     planner.settings.max_acceleration_mm_per_s2[X_AXIS] = 100;
     planner.settings.max_acceleration_mm_per_s2[Y_AXIS] = 100;
+    TERN_(DELTA, planner.settings.max_acceleration_mm_per_s2[Z_AXIS] = 100);
     #if HAS_CLASSIC_JERK
       motion_state.jerk_state = planner.max_jerk;
-      planner.max_jerk.set(0, 0);
+      planner.max_jerk.set(0, 0 OPTARG(DELTA, 0));
     #endif
     planner.reset_acceleration_rates();
     return motion_state;
@@ -181,6 +184,7 @@
   void end_slow_homing(const motion_state_t &motion_state) {
     planner.settings.max_acceleration_mm_per_s2[X_AXIS] = motion_state.acceleration.x;
     planner.settings.max_acceleration_mm_per_s2[Y_AXIS] = motion_state.acceleration.y;
+    TERN_(DELTA, planner.settings.max_acceleration_mm_per_s2[Z_AXIS] = motion_state.acceleration.z);
     TERN_(HAS_CLASSIC_JERK, planner.max_jerk = motion_state.jerk_state);
     planner.reset_acceleration_rates();
   }
@@ -259,7 +263,7 @@ void GcodeSuite::G28() {
   reset_stepper_timeout();
 
   #define HAS_CURRENT_HOME(N) (defined(N##_CURRENT_HOME) && N##_CURRENT_HOME != N##_CURRENT)
-  #if HAS_CURRENT_HOME(X) || HAS_CURRENT_HOME(X2) || HAS_CURRENT_HOME(Y) || HAS_CURRENT_HOME(Y2)
+  #if HAS_CURRENT_HOME(X) || HAS_CURRENT_HOME(X2) || HAS_CURRENT_HOME(Y) || HAS_CURRENT_HOME(Y2) || (ENABLED(DELTA) && HAS_CURRENT_HOME(Z))
     #define HAS_HOMING_CURRENT 1
   #endif
 
@@ -287,6 +291,11 @@ void GcodeSuite::G28() {
       stepperY2.rms_current(Y2_CURRENT_HOME);
       if (DEBUGGING(LEVELING)) debug_current(PSTR("Y2"), tmc_save_current_Y2, Y2_CURRENT_HOME);
     #endif
+    #if HAS_CURRENT_HOME(Z) && ENABLED(DELTA)
+      const int16_t tmc_save_current_Z = stepperZ.getMilliamps();
+      stepperZ.rms_current(Z_CURRENT_HOME);
+      if (DEBUGGING(LEVELING)) debug_current(PSTR("Z"), tmc_save_current_Z, Z_CURRENT_HOME);
+    #endif
   #endif
 
   #if ENABLED(IMPROVE_HOMING_RELIABILITY)
@@ -497,6 +506,9 @@ void GcodeSuite::G28() {
     #if HAS_CURRENT_HOME(Y2)
       stepperY2.rms_current(tmc_save_current_Y2);
     #endif
+    #if HAS_CURRENT_HOME(Z) && ENABLED(DELTA)
+      stepperZ.rms_current(tmc_save_current_Z);
+    #endif
     #if HAS_CURRENT_HOME(I)
       stepperI.rms_current(tmc_save_current_I);
     #endif

Marlin/src/gcode/calibrate/G33.cpp

@@ -71,7 +71,9 @@ float lcd_probe_pt(const xy_pos_t &xy);
 
 void ac_home() {
   endstops.enable(true);
+  TERN_(SENSORLESS_HOMING, probe.set_homing_current(true));
   home_delta();
+  TERN_(SENSORLESS_HOMING, probe.set_homing_current(false));
   endstops.not_homing();
 }
 
@@ -384,6 +386,12 @@ static float auto_tune_a() {
  *      V3  Report settings and probe results
  *
  *   E   Engage the probe for each point
+ *
+ * With SENSORLESS_PROBING:
+ *   Use these flags to calibrate stall sensitivity: (e.g., `G33 P1 Y Z` to calibrate X only.)
+ *   X   Don't activate stallguard on X.
+ *   Y   Don't activate stallguard on Y.
+ *   Z   Don't activate stallguard on Z.
  */
 void GcodeSuite::G33() {
 
@@ -417,6 +425,12 @@ void GcodeSuite::G33() {
 
   const bool stow_after_each = parser.seen_test('E');
 
+  #if ENABLED(SENSORLESS_PROBING)
+    probe.test_sensitivity.x = !parser.seen_test('X');
+    TERN_(HAS_Y_AXIS, probe.test_sensitivity.y = !parser.seen_test('Y'));
+    TERN_(HAS_Z_AXIS, probe.test_sensitivity.z = !parser.seen_test('Z'));
+  #endif
+
   const bool _0p_calibration      = probe_points == 0,
              _1p_calibration      = probe_points == 1 || probe_points == -1,
              _4p_calibration      = probe_points == 2,
@@ -587,7 +601,7 @@ void GcodeSuite::G33() {
 
     // print report
 
-    if (verbose_level == 3)
+    if (verbose_level == 3 || verbose_level == 0)
       print_calibration_results(z_at_pt, _tower_results, _opposite_results);
 
     if (verbose_level != 0) { // !dry run

Marlin/src/module/delta.cpp

@@ -254,6 +254,7 @@ void home_delta() {
   current_position.z = DIFF_TERN(HAS_BED_PROBE, delta_height + 10, probe.offset.z);
   line_to_current_position(homing_feedrate(Z_AXIS));
   planner.synchronize();
+  TERN_(SENSORLESS_PROBING,endstops.report_states());
 
   // Re-enable stealthChop if used. Disable diag1 pin on driver.
   #if ENABLED(SENSORLESS_HOMING) && DISABLED(ENDSTOPS_ALWAYS_ON_DEFAULT)

Marlin/src/module/endstops.cpp

@@ -595,9 +595,15 @@ void _O2 Endstops::report_states() {
 // The following routines are called from an ISR context. It could be the temperature ISR, the
 // endstop ISR or the Stepper ISR.
 
-#define _ENDSTOP(AXIS, MINMAX) AXIS ##_## MINMAX
+#if BOTH(DELTA, SENSORLESS_PROBING)
-#define _ENDSTOP_PIN(AXIS, MINMAX) AXIS ##_## MINMAX ##_PIN
+  #define _ENDSTOP(AXIS, MINMAX) AXIS ##_MAX
-#define _ENDSTOP_INVERTING(AXIS, MINMAX) AXIS ##_## MINMAX ##_ENDSTOP_INVERTING
+  #define _ENDSTOP_PIN(AXIS, MINMAX) AXIS ##_MAX_PIN
+  #define _ENDSTOP_INVERTING(AXIS, MINMAX) AXIS ##_MAX_ENDSTOP_INVERTING
+#else
+  #define _ENDSTOP(AXIS, MINMAX) AXIS ##_## MINMAX
+  #define _ENDSTOP_PIN(AXIS, MINMAX) AXIS ##_## MINMAX ##_PIN
+  #define _ENDSTOP_INVERTING(AXIS, MINMAX) AXIS ##_## MINMAX ##_ENDSTOP_INVERTING
+#endif
 
 // Check endstops - Could be called from Temperature ISR!
 void Endstops::update() {

Marlin/src/module/planner.cpp

@@ -1527,6 +1527,34 @@ void Planner::check_axes_activity() {
   }
 #endif
 
+#if ENABLED(IMPROVE_HOMING_RELIABILITY)
+
+  void Planner::enable_stall_prevention(const bool onoff) {
+    static motion_state_t saved_motion_state;
+    if (onoff) {
+      saved_motion_state.acceleration.x = settings.max_acceleration_mm_per_s2[X_AXIS];
+      saved_motion_state.acceleration.y = settings.max_acceleration_mm_per_s2[Y_AXIS];
+      settings.max_acceleration_mm_per_s2[X_AXIS] = settings.max_acceleration_mm_per_s2[Y_AXIS] = 100;
+      #if ENABLED(DELTA)
+        saved_motion_state.acceleration.z = settings.max_acceleration_mm_per_s2[Z_AXIS];
+        settings.max_acceleration_mm_per_s2[Z_AXIS] = 100;
+      #endif
+      #if HAS_CLASSIC_JERK
+        saved_motion_state.jerk_state = max_jerk;
+        max_jerk.set(0, 0 OPTARG(DELTA, 0));
+      #endif
+    }
+    else {
+      settings.max_acceleration_mm_per_s2[X_AXIS] = saved_motion_state.acceleration.x;
+      settings.max_acceleration_mm_per_s2[Y_AXIS] = saved_motion_state.acceleration.y;
+      TERN_(DELTA, settings.max_acceleration_mm_per_s2[Z_AXIS] = saved_motion_state.acceleration.z);
+      TERN_(HAS_CLASSIC_JERK, max_jerk = saved_motion_state.jerk_state);
+    }
+    reset_acceleration_rates();
+  }
+
+#endif
+
 #if HAS_LEVELING
 
   constexpr xy_pos_t level_fulcrum = {

Marlin/src/module/planner.h

@@ -281,6 +281,15 @@ typedef struct {
             min_travel_feedrate_mm_s;           // (mm/s) M205 T - Minimum travel feedrate
 } planner_settings_t;
 
+#if ENABLED(IMPROVE_HOMING_RELIABILITY)
+  struct motion_state_t {
+    TERN(DELTA, xyz_ulong_t, xy_ulong_t) acceleration;
+    #if HAS_CLASSIC_JERK
+      TERN(DELTA, xyz_float_t, xy_float_t) jerk_state;
+    #endif
+  };
+#endif
+
 #if DISABLED(SKEW_CORRECTION)
   #define XY_SKEW_FACTOR 0
   #define XZ_SKEW_FACTOR 0
@@ -532,6 +541,10 @@ class Planner {
       }
     #endif
 
+    #if ENABLED(IMPROVE_HOMING_RELIABILITY)
+      void enable_stall_prevention(const bool onoff);
+    #endif
+
     #if DISABLED(NO_VOLUMETRICS)
 
       // Update multipliers based on new diameter measurements

Marlin/src/module/probe.cpp

@@ -68,7 +68,7 @@
   #include "servo.h"
 #endif
 
-#if ENABLED(SENSORLESS_PROBING)
+#if EITHER(SENSORLESS_PROBING, SENSORLESS_HOMING)
   #include "stepper.h"
   #include "../feature/tmc_util.h"
 #endif
@@ -92,6 +92,10 @@ xyz_pos_t Probe::offset; // Initialized by settings.load()
   const xy_pos_t &Probe::offset_xy = Probe::offset;
 #endif
 
+#if ENABLED(SENSORLESS_PROBING)
+  Probe::sense_bool_t Probe::test_sensitivity;
+#endif
+
 #if ENABLED(Z_PROBE_SLED)
 
   #ifndef SLED_DOCKING_OFFSET
@@ -493,11 +497,12 @@ bool Probe::probe_down_to_z(const_float_t z, const_feedRate_t fr_mm_s) {
   #if ENABLED(SENSORLESS_PROBING)
     sensorless_t stealth_states { false };
     #if ENABLED(DELTA)
-      stealth_states.x = tmc_enable_stallguard(stepperX);
+      if (probe.test_sensitivity.x) stealth_states.x = tmc_enable_stallguard(stepperX);  // Delta watches all DIAG pins for a stall
-      stealth_states.y = tmc_enable_stallguard(stepperY);
+      if (probe.test_sensitivity.y) stealth_states.y = tmc_enable_stallguard(stepperY);
     #endif
-    stealth_states.z = tmc_enable_stallguard(stepperZ);
+    if (probe.test_sensitivity.z) stealth_states.z = tmc_enable_stallguard(stepperZ);    // All machines will check Z-DIAG for stall
     endstops.enable(true);
+    set_homing_current(true);                                 // The "homing" current also applies to probing
   #endif
 
   TERN_(HAS_QUIET_PROBING, set_probing_paused(true));
@@ -520,10 +525,11 @@ bool Probe::probe_down_to_z(const_float_t z, const_feedRate_t fr_mm_s) {
   #if ENABLED(SENSORLESS_PROBING)
     endstops.not_homing();
     #if ENABLED(DELTA)
-      tmc_disable_stallguard(stepperX, stealth_states.x);
+      if (probe.test_sensitivity.x) tmc_disable_stallguard(stepperX, stealth_states.x);
-      tmc_disable_stallguard(stepperY, stealth_states.y);
+      if (probe.test_sensitivity.y) tmc_disable_stallguard(stepperY, stealth_states.y);
     #endif
-    tmc_disable_stallguard(stepperZ, stealth_states.z);
+    if (probe.test_sensitivity.z) tmc_disable_stallguard(stepperZ, stealth_states.z);
+    set_homing_current(false);
   #endif
 
   if (probe_triggered && TERN0(BLTOUCH_SLOW_MODE, bltouch.stow())) // Stow in LOW SPEED MODE on every trigger
@@ -815,4 +821,93 @@ float Probe::probe_at_point(const_float_t rx, const_float_t ry, const ProbePtRai
 
 #endif // HAS_Z_SERVO_PROBE
 
+#if EITHER(SENSORLESS_PROBING, SENSORLESS_HOMING)
+
+  sensorless_t stealth_states { false };
+
+  /**
+   * Disable stealthChop if used. Enable diag1 pin on driver.
+   */
+  void Probe::enable_stallguard_diag1() {
+    #if ENABLED(SENSORLESS_PROBING)
+      #if ENABLED(DELTA)
+        stealth_states.x = tmc_enable_stallguard(stepperX);
+        stealth_states.y = tmc_enable_stallguard(stepperY);
+      #endif
+      stealth_states.z = tmc_enable_stallguard(stepperZ);
+      endstops.enable(true);
+    #endif
+  }
+
+  /**
+   * Re-enable stealthChop if used. Disable diag1 pin on driver.
+   */
+  void Probe::disable_stallguard_diag1() {
+    #if ENABLED(SENSORLESS_PROBING)
+      endstops.not_homing();
+      #if ENABLED(DELTA)
+        tmc_disable_stallguard(stepperX, stealth_states.x);
+        tmc_disable_stallguard(stepperY, stealth_states.y);
+      #endif
+      tmc_disable_stallguard(stepperZ, stealth_states.z);
+    #endif
+  }
+
+  /**
+   * Change the current in the TMC drivers to N##_CURRENT_HOME. And we save the current configuration of each TMC driver.
+   */
+  void Probe::set_homing_current(const bool onoff) {
+    #define HAS_CURRENT_HOME(N) (defined(N##_CURRENT_HOME) && N##_CURRENT_HOME != N##_CURRENT)
+    #if HAS_CURRENT_HOME(X) || HAS_CURRENT_HOME(Y) || HAS_CURRENT_HOME(Z)
+      #if ENABLED(DELTA)
+        static int16_t saved_current_X, saved_current_Y;
+      #endif
+      #if HAS_CURRENT_HOME(Z)
+        static int16_t saved_current_Z;
+      #endif
+      auto debug_current_on = [](PGM_P const s, const int16_t a, const int16_t b) {
+        if (DEBUGGING(LEVELING)) { DEBUG_ECHOPGM_P(s); DEBUG_ECHOLNPAIR(" current: ", a, " -> ", b); }
+      };
+      if (onoff) {
+        #if ENABLED(DELTA)
+          #if HAS_CURRENT_HOME(X)
+            saved_current_X = stepperX.getMilliamps();
+            stepperX.rms_current(X_CURRENT_HOME);
+            debug_current_on(PSTR("X"), saved_current_X, X_CURRENT_HOME);
+          #endif
+          #if HAS_CURRENT_HOME(Y)
+            saved_current_Y = stepperY.getMilliamps();
+            stepperY.rms_current(Y_CURRENT_HOME);
+            debug_current_on(PSTR("Y"), saved_current_Y, Y_CURRENT_HOME);
+          #endif
+        #endif
+        #if HAS_CURRENT_HOME(Z)
+          saved_current_Z = stepperZ.getMilliamps();
+          stepperZ.rms_current(Z_CURRENT_HOME);
+          debug_current_on(PSTR("Z"), saved_current_Z, Z_CURRENT_HOME);
+        #endif
+        TERN_(IMPROVE_HOMING_RELIABILITY, planner.enable_stall_prevention(true));
+      }
+      else {
+        #if ENABLED(DELTA)
+          #if HAS_CURRENT_HOME(X)
+            stepperX.rms_current(saved_current_X);
+            debug_current_on(PSTR("X"), X_CURRENT_HOME, saved_current_X);
+          #endif
+          #if HAS_CURRENT_HOME(Y)
+            stepperY.rms_current(saved_current_Y);
+            debug_current_on(PSTR("Y"), Y_CURRENT_HOME, saved_current_Y);
+          #endif
+        #endif
+        #if HAS_CURRENT_HOME(Z)
+          stepperZ.rms_current(saved_current_Z);
+          debug_current_on(PSTR("Z"), Z_CURRENT_HOME, saved_current_Z);
+        #endif
+        TERN_(IMPROVE_HOMING_RELIABILITY, planner.enable_stall_prevention(false));
+      }
+    #endif
+  }
+
+#endif // SENSORLESS_PROBING
+
 #endif // HAS_BED_PROBE

Marlin/src/module/probe.h

@@ -56,6 +56,11 @@
 class Probe {
 public:
 
+  #if ENABLED(SENSORLESS_PROBING)
+    typedef struct { bool x:1, y:1, z:1; } sense_bool_t;
+    static sense_bool_t test_sensitivity;
+  #endif
+
   #if HAS_BED_PROBE
 
     static xyz_pos_t offset;
@@ -256,6 +261,13 @@ public:
     static bool tare();
   #endif
 
+  // Basic functions for Sensorless Homing and Probing
+  #if EITHER(SENSORLESS_HOMING, SENSORLESS_PROBING)
+    static void enable_stallguard_diag1();
+    static void disable_stallguard_diag1();
+    static void set_homing_current(const bool onoff);
+  #endif
+
 private:
   static bool probe_down_to_z(const_float_t z, const_feedRate_t fr_mm_s);
   static void do_z_raise(const float z_raise);