Merge pull request #64 from simonepri/master

Update 4.1.5 dev

Documentation/CurrentSensor.md

+Power consumption sensor (Hall effect sensor like ACS712)
+---------------------------------------------------------
+Support for a current sensor (Hall effect sensor like ACS712) for measure the power consumption
+Since it's more simple to deal with, we measure the DC current and we assume that POWER_VOLTAGE that comes from your power supply it's almost stable.
+You have to change the POWER_SENSITIVITY with the one that you can find in the datasheet. (in case of ACS712: set to .100 for 20A version or set .066 for 30A version)
+
+After setted POWER_VOLTAGE and POWER_SENSITIVITY you have to found correct value for POWER_ZERO.
+You can do it by using "M70 Z" gcode and read the calculated value from serial messages.
+Before calling "M70 Z" you have to disconnect the cable for measure the current from the sensor leaving only +5, OUT and GND connections.
+Insert new values into FW and recompile.
+Now you can reconnect the current cable to the sensor.
+
+Now you have to set right value for POWER_ERROR.
+Get a good multimeter and meacure DC current coming out from the power supply.
+In order to get an accurate value power-on something (Eg. Heater, Motor, Fan) DO NOT POWER-ON THE BED OR YOU MAY KILL IT!!!!
+Call "M70 Ax" where 'x' is the value measured by the multimeter.
+Insert new values into FW and recompile.
+
+With this module we measure the Printer power consumption ignoring the Power Supply power consumption,
+so we consider the POWER_EFFICIENCY of our supply to be 100%.
+WARNING: from this moment the procedure can be REALLY HARMFUL to health unless you have a little experience so DO NOT DO IT IF YOU DO NOT KNOW WHAT YOU ARE DOING!!!
+If you want to approximately add the supply consumption you have measure the AC current with a good multimeter
+and moltiple it with the mains voltage (110V AC - 220V AC).
+MULTIMETER_WATT = MULTIMETER_CURRENTMAINS_VOLTAGE
+Call "M70 Wx" where 'x' is MULTIMETER_WATT;
+Insert new values into FW and recompile.
+
+Now you AC712 it should be calibrated.
\ No newline at end of file

Documentation/changelog.md

 ### Version 4.1.5
+* Added M70 gcode for calibrate AC721 current sensor
+* Added documentation for calibrate AC721 current sensor
 * Critical stepper motor frequency bugfix
 * Introduced more intuitive menu tree.
 * Added a menu option to fix loose steps from LCD

MarlinKimbra/Configuration.h

@@ -623,23 +623,39 @@
 /**********************************************************************\
  * Support for a current sensor (Hall effect sensor like ACS712) for measure the power consumption
  * Since it's more simple to deal with, we measure the DC current and we assume that POWER_VOLTAGE that comes from your power supply it's almost stable.
- * You have to change the SENSITIVITY with the one that you can find in the datasheet. (in case of ACS712: set to .100 for 20A version or set .066 for 30A version)
- * With this module we measure the Printer power consumption ignoring the Power Supply power consumption, so we consider the EFFICIENCY of our supply to be 100% so without
- * any power dispersion. If you want to approximately add the supply consumption you can decrease the EFFICIENCY to a value less than 100. Eg: 85 is a good value.
- * You can find a better value measuring the AC current with a good multimeter and moltiple it with the mains voltage.
- * MULTIMETER_WATT := MULTIMETER_CURRENT * MAINS_VOLTAGE
- * Now you have a Wattage value that you can compare with the one measured from ACS712.
- * NEW_EFFICENCY := (SENSOR_WATT*EFFICIENCY)/MULTIMETER_WATT
- * For now this feature is to be consider BETA as i'll have to do some accurate test to see the affidability
+ * You have to change the POWER_SENSITIVITY with the one that you can find in the datasheet. (in case of ACS712: set to .100 for 20A version or set .066 for 30A version)
+ *
+ * After setted POWER_VOLTAGE and POWER_SENSITIVITY you have to found correct value for POWER_ZERO
+ * You can do it by using "M70 Z" gcode and read the calculated value from serial messages.
+ * Before calling "M70 Z" you have to disconnect the cable for measure the current from the sensor leaving only +5, OUT and GND connections.
+ * Insert new values into FW and recompile.
+ * Now you can reconnect the current cable to the sensor.
+ *
+ * Now you have to set right value for POWER_ERROR.
+ * Get a good multimeter and meacure DC current coming out from the power supply.
+ * In order to get an accurate value power-on something (Eg. Heater, Motor, Fan) DO NOT POWER-ON THE BED OR YOU MAY KILL IT!!!!
+ * Call "M70 Ax" where 'x' is the value measured by the multimeter.
+ * Insert new values into FW and recompile.
+ *
+ * With this module we measure the Printer power consumption ignoring the Power Supply power consumption,
+ * so we consider the POWER_EFFICIENCY of our supply to be 100%.
+ * WARNING: from this moment the procedure can be REALLY HARMFUL to health unless you have a little experience so DO NOT DO IT IF YOU DO NOT KNOW WHAT YOU ARE DOING!!!
+ * If you want to approximately add the supply consumption you have measure the AC current with a good multimeter
+ * and moltiple it with the mains voltage (110V AC - 220V AC).
+ * MULTIMETER_WATT = MULTIMETER_CURRENT * MAINS_VOLTAGE
+ * Call "M70 Wx" where 'x' is MULTIMETER_WATT;
+ * Insert new values into FW and recompile.
+ *
+ * Now you AC712 it should be calibrated.
  **********************************************************************/
 // Uncomment below to enable
 //#define POWER_CONSUMPTION
 #if ENABLED(POWER_CONSUMPTION)
 #define POWER_VOLTAGE      12.00    //(V) The power supply OUT voltage
-#define POWER_ZERO          2.54459 //(V) The /\V coming out from the sensor when no current flow.
 #define POWER_SENSITIVITY   0.066   //(V/A) How much increase V for 1A of increase
-#define POWER_OFFSET        0.015   //(A) Help to get 0A when no load is connected.
-#define POWER_ERROR         3.0     //(%) Ammortize measure error.
+#define POWER_OFFSET        0.005   //(A) Help to get 0A when no load is connected.
+#define POWER_ZERO          2.500   //(V) The /\V coming out from the sensor when no current flow.
+#define POWER_ERROR         0.0     //(%) Ammortize measure error.
 #define POWER_EFFICIENCY  100.0     //(%) The power efficency of the power supply
 
 //When using an LCD, uncomment the line below to display the Power consumption sensor data on the last line instead of status.  Status will appear for 5 sec.

MarlinKimbra/Marlin.h

@@ -293,6 +293,9 @@ extern int fanSpeed;
   extern unsigned long power_consumption_hour;  //holds the power consumption per hour as accurately measured
   extern unsigned long startpower;
   extern unsigned long stoppower;
+  extern float raw_analog2voltage();
+  extern float analog2error(float current);
+  extern float analog2efficiency(float watt);
 #endif
 
 #if ENABLED(IDLE_OOZING_PREVENT)

MarlinKimbra/Marlin_main.cpp

@@ -132,6 +132,7 @@
  * M33  - Get the longname version of a path
  * M42  - Change pin status via gcode Use M42 Px Sy to set pin x to value y, when omitting Px the onboard led will be used.
  * M48  - Measure Z_Probe repeatability. M48 [P # of points] [X position] [Y position] [V_erboseness #] [E_ngage Probe] [L # of legs of travel]
+ * M70  - Power consumption sensor calibration
  * M80  - Turn on Power Supply
  * M81  - Turn off Power Supply
  * M82  - Set E codes absolute (default)
@@ -4693,6 +4694,34 @@ inline void gcode_M42() {
 
 #endif // AUTO_BED_LEVELING_FEATURE && Z_PROBE_REPEATABILITY_TEST
 
+#if HAS_POWER_CONSUMPTION_SENSOR
+
+  /**
+   * M70 - Power consumption sensor calibration
+   *
+   * Z - Calibrate zero current offset
+   * A - Isert readed DC Current value (Ampere)
+   * W - Insert readed AC Wattage value (Watt)
+   */
+  inline void gcode_M70() {
+    if(code_seen('Z')) {
+      ECHO_EMV("Actual POWER_ZERO:", POWER_ZERO, 7);
+      ECHO_EMV("New POWER_ZERO:", raw_analog2voltage(), 7);
+      ECHO_EM("Insert new calculated values into the FW and call \"M70 A\" for the next calibration step.");
+    }
+    else if(code_seen('A')) {
+      ECHO_EMV("Actual POWER_ERROR:", POWER_ERROR, 7);
+      ECHO_EMV("New POWER_ERROR:", analog2error(code_value()), 7);
+      ECHO_EM("Insert new calculated values into the FW and call \"M70 W\" for the last calibration step.");
+    }
+    else if(code_seen('W')) {
+      ECHO_EMV("Actual POWER_EFFICIENCY:", POWER_EFFICIENCY, 7);
+      ECHO_EMV("New POWER_EFFICIENCY:", analog2efficiency(code_value()), 7);
+      ECHO_EM("Insert new calculated values into the FW and then ACS712 it should be calibrated correctly.");
+    }
+  }
+#endif
+
 #if HAS_POWER_SWITCH
 
   /**
@@ -6766,6 +6795,11 @@ void process_next_command() {
           gcode_M48(); break;
       #endif
       
+      #if HAS_POWER_CONSUMPTION_SENSOR
+        case 70: // M70 - Power consumption sensor calibration
+          gcode_M70(); break;
+      #endif
+      
       #if HAS_POWER_SWITCH
         case 80: // M80 - Turn on Power Supply
           gcode_M80(); break;

MarlinKimbra/conditionals.h

@@ -384,13 +384,6 @@
     #define Z_SAFE_HOMING
   #endif
 
-  /**
-   * Babystepping
-   */
-  #if ENABLED(CARTESIAN)
-    #define BABYSTEPPING  // On Cartesian printer this can be enabled as default as fully working
-  #endif
-
   /**
    * MAX_STEP_FREQUENCY differs for TOSHIBA OR ARDUINO DUE OR ARDUINO MEGA
    */

MarlinKimbra/temperature.cpp

@@ -804,7 +804,10 @@ static void updateTemperaturesFromRawValues() {
   #if HAS_POWER_CONSUMPTION_SENSOR
     static float watt_overflow = 0.0;
     power_consumption_meas = analog2power();
-    //MYSERIAL.println(analog2current(),3);
+    /*ECHO_MV("raw:", raw_analog2voltage(), 5);
+    ECHO_MV(" - V:", analog2voltage(), 5);
+    ECHO_MV(" - I:", analog2current(), 5);
+    ECHO_EMV(" - P:", analog2power(), 5);*/
     watt_overflow += (power_consumption_meas * from_last_update) / 3600000.0;
     if (watt_overflow >= 1.0) {
       power_consumption_hour++;
@@ -850,14 +853,34 @@ static void updateTemperaturesFromRawValues() {
 
 #if HAS_POWER_CONSUMPTION_SENSOR
   // Convert raw Power Consumption to watt
+  float raw_analog2voltage() {
+    return (5.0 * current_raw_powconsumption) / (1023 * OVERSAMPLENR);
+  }
+  
+  float analog2voltage() {
+    float power_zero_raw = (POWER_ZERO * 1023 * OVERSAMPLENR) / 5.0;
+    float rel_raw_power = (current_raw_powconsumption < power_zero_raw) ? (2 * power_zero_raw - current_raw_powconsumption) : (current_raw_powconsumption);
+    return ((5.0 * rel_raw_power) / (1023 * OVERSAMPLENR)) - POWER_ZERO;
+  }
   float analog2current() {
-    float temp = (((5.0 * current_raw_powconsumption) / (1023 * OVERSAMPLENR)) - POWER_ZERO) / POWER_SENSITIVITY;
-    temp = ((100 - POWER_ERROR) / 100) * (temp + (temp / 100)) - POWER_OFFSET;
+    float temp = analog2voltage() / POWER_SENSITIVITY;
+    temp = (((100 - POWER_ERROR) / 100) * temp) - POWER_OFFSET;
     return temp > 0 ? temp : 0;
   }
   float analog2power() {
     return (analog2current() * POWER_VOLTAGE * 100) /  POWER_EFFICIENCY;
   }
+  
+  float analog2error(float current) {
+    float temp1 = (analog2voltage() / POWER_SENSITIVITY - POWER_OFFSET) * POWER_VOLTAGE;
+    if(temp1 <= 0) return 0.0;
+    float temp2 = (current) * POWER_VOLTAGE;
+    if(temp2 <= 0) return 0.0;
+    return ((temp2/temp1)-1)*100;
+  }
+  float analog2efficiency(float watt) {
+    return (analog2current() * POWER_VOLTAGE * 100) / watt;
+  }
 #endif
 
 /**
@@ -1301,12 +1324,7 @@ static void set_current_temp_raw() {
   current_temperature_bed_raw = raw_temp_bed_value;
 
   #if HAS_POWER_CONSUMPTION_SENSOR
-    #ifdef __SAM3X8E__
-      float power_zero_raw = (POWER_ZERO * 1023 * OVERSAMPLENR) / 3.3;
-    #else
-      float power_zero_raw = (POWER_ZERO * 1023 * OVERSAMPLENR) / 5.0;
-    #endif
-    current_raw_powconsumption = (raw_powconsumption_value < power_zero_raw) ? (2 * power_zero_raw - raw_powconsumption_value) : (raw_powconsumption_value);
+    current_raw_powconsumption = raw_powconsumption_value;
   #endif
   temp_meas_ready = true;
 }

MarlinKimbra/temperature.h

@@ -39,8 +39,12 @@ void manage_heater(); //it is critical that this is called periodically.
 
 #if HAS_POWER_CONSUMPTION_SENSOR
   // For converting raw Power Consumption to watt
+  float analog2voltage();
   float analog2current();
   float analog2power();
+  float raw_analog2voltage();
+  float analog2error(float current);
+  float analog2efficiency(float watt);
 #endif
 
 // low level conversion routines

README.md

 <img align="right" src="Documentation/Logo/MarlinKimbra%20Logo%20GitHub.png" />
 # MarlinKimbra 3D Printer Firmware
-## Version 4.1.5 RC (Release Candidate)
+## Version 4.1.5 dev
 
   * [Configuration & Compilation](/Documentation/Compilation.md)
   * Supported