Fix and improve POWER_LOSS_RECOVERY (#11187)

Marlin/src/Marlin.cpp

@@ -897,7 +897,7 @@ void setup() {
   #endif
 
   #if ENABLED(POWER_LOSS_RECOVERY)
-    do_print_job_recovery();
+    check_print_job_recovery();
   #endif
 
   #if ENABLED(USE_WATCHDOG) // Reinit watchdog after HAL_get_reset_source call
@@ -937,6 +937,9 @@ void loop() {
           for (uint8_t i = 0; i < FAN_COUNT; i++) fanSpeeds[i] = 0;
         #endif
         wait_for_heatup = false;
+        #if ENABLED(POWER_LOSS_RECOVERY)
+          card.removeJobRecoveryFile();
+        #endif
       }
     #endif // SDSUPPORT && ULTIPANEL
 

Marlin/src/feature/power_loss_recovery.cpp

@@ -43,14 +43,14 @@ job_recovery_info_t job_recovery_info;
 JobRecoveryPhase job_recovery_phase = JOB_RECOVERY_IDLE;
 uint8_t job_recovery_commands_count; //=0
 char job_recovery_commands[BUFSIZE + APPEND_CMD_COUNT][MAX_CMD_SIZE];
-
-// Private
-static char sd_filename[MAXPATHNAMELENGTH];
+// Extern
+extern uint8_t active_extruder, commands_in_queue, cmd_queue_index_r;
 
 #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
   void debug_print_job_recovery(const bool recovery) {
-    SERIAL_PROTOCOLPAIR("valid_head:", (int)job_recovery_info.valid_head);
-    SERIAL_PROTOCOLLNPAIR(" valid_foot:", (int)job_recovery_info.valid_foot);
+    SERIAL_PROTOCOLLNPGM("---- Job Recovery Info ----");
+    SERIAL_PROTOCOLPAIR("valid_head:", int(job_recovery_info.valid_head));
+    SERIAL_PROTOCOLLNPAIR(" valid_foot:", int(job_recovery_info.valid_foot));
     if (job_recovery_info.valid_head) {
       if (job_recovery_info.valid_head == job_recovery_info.valid_foot) {
         SERIAL_PROTOCOLPGM("current_position: ");
@@ -60,6 +60,11 @@ static char sd_filename[MAXPATHNAMELENGTH];
         }
         SERIAL_EOL();
         SERIAL_PROTOCOLLNPAIR("feedrate: ", job_recovery_info.feedrate);
+
+        #if HOTENDS > 1
+          SERIAL_PROTOCOLLNPAIR("active_hotend: ", int(job_recovery_info.active_hotend));
+        #endif
+
         SERIAL_PROTOCOLPGM("target_temperature: ");
         HOTEND_LOOP() {
           SERIAL_PROTOCOL(job_recovery_info.target_temperature[e]);
@@ -84,8 +89,8 @@ static char sd_filename[MAXPATHNAMELENGTH];
           SERIAL_PROTOCOLPAIR("leveling: ", int(job_recovery_info.leveling));
           SERIAL_PROTOCOLLNPAIR(" fade: ", int(job_recovery_info.fade));
         #endif
-        SERIAL_PROTOCOLLNPAIR("cmd_queue_index_r: ", job_recovery_info.cmd_queue_index_r);
-        SERIAL_PROTOCOLLNPAIR("commands_in_queue: ", job_recovery_info.commands_in_queue);
+        SERIAL_PROTOCOLLNPAIR("cmd_queue_index_r: ", int(job_recovery_info.cmd_queue_index_r));
+        SERIAL_PROTOCOLLNPAIR("commands_in_queue: ", int(job_recovery_info.commands_in_queue));
         if (recovery)
           for (uint8_t i = 0; i < job_recovery_commands_count; i++) SERIAL_PROTOCOLLNPAIR("> ", job_recovery_commands[i]);
         else
@@ -97,15 +102,17 @@ static char sd_filename[MAXPATHNAMELENGTH];
       else
         SERIAL_PROTOCOLLNPGM("INVALID DATA");
     }
+    SERIAL_PROTOCOLLNPGM("---------------------------");
   }
 #endif // DEBUG_POWER_LOSS_RECOVERY
 
 /**
- * Check for Print Job Recovery
- * If the file has a saved state, populate the job_recovery_commands queue
+ * Check for Print Job Recovery during setup()
+ *
+ * If a saved state exists, populate job_recovery_commands with
+ * commands to restore the machine state and continue the file.
  */
-void do_print_job_recovery() {
-  //if (job_recovery_commands_count > 0) return;
+void check_print_job_recovery() {
   memset(&job_recovery_info, 0, sizeof(job_recovery_info));
   ZERO(job_recovery_commands);
 
@@ -114,7 +121,7 @@ void do_print_job_recovery() {
   if (card.cardOK) {
 
     #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      SERIAL_PROTOCOLLNPAIR("Init job recovery info. Size: ", (int)sizeof(job_recovery_info));
+      SERIAL_PROTOCOLLNPAIR("Init job recovery info. Size: ", int(sizeof(job_recovery_info)));
     #endif
 
     if (card.jobRecoverFileExists()) {
@@ -134,7 +141,9 @@ void do_print_job_recovery() {
         strcpy_P(job_recovery_commands[ind++], PSTR("G92.0 Z0"));                   // Ensure Z is equal to 0
         strcpy_P(job_recovery_commands[ind++], PSTR("G1 Z2"));                      // Raise Z by 2mm (we hope!)
         strcpy_P(job_recovery_commands[ind++], PSTR("G28 R0"
-          #if !IS_KINEMATIC
+          #if ENABLED(MARLIN_DEV_MODE)
+            " S"
+          #elif !IS_KINEMATIC
             " X Y"                                                                  // Home X and Y for Cartesian
           #endif
         ));
@@ -142,10 +151,12 @@ void do_print_job_recovery() {
         char str_1[16], str_2[16];
 
         #if HAS_LEVELING
-          // Restore leveling state before G92 sets Z
-          // This ensures the steppers correspond to the native Z
-          dtostrf(job_recovery_info.fade, 1, 1, str_1);
-          sprintf_P(job_recovery_commands[ind++], PSTR("M420 S%i Z%s"), int(job_recovery_info.leveling), str_1);
+          if (job_recovery_info.fade || job_recovery_info.leveling) {
+            // Restore leveling state before G92 sets Z
+            // This ensures the steppers correspond to the native Z
+            dtostrf(job_recovery_info.fade, 1, 1, str_1);
+            sprintf_P(job_recovery_commands[ind++], PSTR("M420 S%i Z%s"), int(job_recovery_info.leveling), str_1);
+          }
         #endif
 
         dtostrf(job_recovery_info.current_position[Z_AXIS] + 2, 1, 3, str_1);
@@ -157,23 +168,21 @@ void do_print_job_recovery() {
         );
         sprintf_P(job_recovery_commands[ind++], PSTR("G92.0 Z%s E%s"), str_1, str_2); // Current Z + 2 and E
 
-        strcpy_P(job_recovery_commands[ind++], PSTR("M117 Continuing..."));
-
-        uint8_t r = job_recovery_info.cmd_queue_index_r;
-        while (job_recovery_info.commands_in_queue) {
+        uint8_t r = job_recovery_info.cmd_queue_index_r, c = job_recovery_info.commands_in_queue;
+        while (c--) {
           strcpy(job_recovery_commands[ind++], job_recovery_info.command_queue[r]);
-          job_recovery_info.commands_in_queue--;
           r = (r + 1) % BUFSIZE;
         }
 
+        if (job_recovery_info.sd_filename[0] == '/') job_recovery_info.sd_filename[0] = ' ';
+        sprintf_P(job_recovery_commands[ind++], PSTR("M23 %s"), job_recovery_info.sd_filename);
+        sprintf_P(job_recovery_commands[ind++], PSTR("M24 S%ld T%ld"), job_recovery_info.sdpos, job_recovery_info.print_job_elapsed);
+
         job_recovery_commands_count = ind;
 
         #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
           debug_print_job_recovery(true);
         #endif
-
-        card.openFile(job_recovery_info.sd_filename, true);
-        card.setIndex(job_recovery_info.sdpos);
       }
       else {
         if (job_recovery_info.valid_head != job_recovery_info.valid_foot)
@@ -213,6 +222,11 @@ void save_job_recovery_info() {
     // Machine state
     COPY(job_recovery_info.current_position, current_position);
     job_recovery_info.feedrate = feedrate_mm_s;
+
+    #if HOTENDS > 1
+      job_recovery_info.active_hotend = active_extruder;
+    #endif
+
     COPY(job_recovery_info.target_temperature, thermalManager.target_temperature);
 
     #if HAS_HEATED_BED
@@ -240,14 +254,14 @@ void save_job_recovery_info() {
     COPY(job_recovery_info.command_queue, command_queue);
 
     // Elapsed print job time
-    job_recovery_info.print_job_elapsed = print_job_timer.duration() * 1000UL;
+    job_recovery_info.print_job_elapsed = print_job_timer.duration();
 
     // SD file position
     card.getAbsFilename(job_recovery_info.sd_filename);
     job_recovery_info.sdpos = card.getIndex();
 
     #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      SERIAL_PROTOCOLLNPGM("Saving job_recovery_info");
+      SERIAL_PROTOCOLLNPGM("Saving...");
       debug_print_job_recovery(false);
     #endif
 

Marlin/src/feature/power_loss_recovery.h

@@ -40,6 +40,11 @@ typedef struct {
 
   // Machine state
   float current_position[NUM_AXIS], feedrate;
+
+  #if HOTENDS > 1
+    uint8_t active_hotend;
+  #endif
+
   int16_t target_temperature[HOTENDS];
 
   #if HAS_HEATED_BED
@@ -74,20 +79,21 @@ extern job_recovery_info_t job_recovery_info;
 enum JobRecoveryPhase : unsigned char {
   JOB_RECOVERY_IDLE,
   JOB_RECOVERY_MAYBE,
-  JOB_RECOVERY_YES
+  JOB_RECOVERY_YES,
+  JOB_RECOVERY_DONE
 };
 extern JobRecoveryPhase job_recovery_phase;
 
 #if HAS_LEVELING
-  #define APPEND_CMD_COUNT 7
+  #define APPEND_CMD_COUNT 9
 #else
-  #define APPEND_CMD_COUNT 5
+  #define APPEND_CMD_COUNT 7
 #endif
 
 extern char job_recovery_commands[BUFSIZE + APPEND_CMD_COUNT][MAX_CMD_SIZE];
 extern uint8_t job_recovery_commands_count;
 
-void do_print_job_recovery();
+void check_print_job_recovery();
 void save_job_recovery_info();
 
 #endif // _POWER_LOSS_RECOVERY_H_

Marlin/src/gcode/queue.cpp

@@ -496,7 +496,7 @@ inline void get_serial_commands() {
       if (job_recovery_commands_count) {
         if (_enqueuecommand(job_recovery_commands[job_recovery_commands_index])) {
           ++job_recovery_commands_index;
-          if (!--job_recovery_commands_count) job_recovery_phase = JOB_RECOVERY_IDLE;
+          if (!--job_recovery_commands_count) job_recovery_phase = JOB_RECOVERY_DONE;
         }
         return true;
       }

Marlin/src/gcode/sdcard/M20-M30_M32-M34_M928.cpp

@@ -72,6 +72,9 @@ void GcodeSuite::M22() { card.release(); }
  * M23: Open a file
  */
 void GcodeSuite::M23() {
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    card.removeJobRecoveryFile();
+  #endif
   // Simplify3D includes the size, so zero out all spaces (#7227)
   for (char *fn = parser.string_arg; *fn; ++fn) if (*fn == ' ') *fn = '\0';
   card.openFile(parser.string_arg, true);
@@ -81,16 +84,22 @@ void GcodeSuite::M23() {
  * M24: Start or Resume SD Print
  */
 void GcodeSuite::M24() {
-  #if ENABLED(POWER_LOSS_RECOVERY)
-    card.removeJobRecoveryFile();
-  #endif
-
   #if ENABLED(PARK_HEAD_ON_PAUSE)
     resume_print();
   #endif
 
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    if (parser.seenval('S')) card.setIndex(parser.value_long());
+  #endif
+
   card.startFileprint();
-  print_job_timer.start();
+
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    if (parser.seenval('T'))
+      print_job_timer.resume(parser.value_long());
+    else
+  #endif
+      print_job_timer.start();
 }
 
 /**

Marlin/src/lcd/language/language_en.h

@@ -666,6 +666,9 @@
 #ifndef MSG_STOP_PRINT
   #define MSG_STOP_PRINT                      _UxGT("Stop print")
 #endif
+#ifndef MSG_POWER_LOSS_RECOVERY
+  #define MSG_POWER_LOSS_RECOVERY             _UxGT("Power-Loss Recovery")
+#endif
 #ifndef MSG_CARD_MENU
   #define MSG_CARD_MENU                       _UxGT("Print from SD")
 #endif

Marlin/src/lcd/ultralcd.cpp

@@ -873,17 +873,13 @@ void lcd_quick_feedback(const bool clear_buttons) {
       abort_sd_printing = true;
       lcd_setstatusPGM(PSTR(MSG_PRINT_ABORTED), -1);
       lcd_return_to_status();
-
-      #if ENABLED(POWER_LOSS_RECOVERY)
-        card.removeJobRecoveryFile();
-      #endif
     }
 
   #endif // SDSUPPORT
 
   #if ENABLED(POWER_LOSS_RECOVERY)
 
-    static void lcd_sdcard_recover_job() {
+    static void lcd_power_loss_recovery_resume() {
       char cmd[20];
 
       // Return to status now
@@ -891,45 +887,65 @@ void lcd_quick_feedback(const bool clear_buttons) {
 
       // Turn leveling off and home
       enqueue_and_echo_commands_P(PSTR("M420 S0\nG28"
-        #if !IS_KINEMATIC
+        #if ENABLED(MARLIN_DEV_MODE)
+          " S"
+        #elif !IS_KINEMATIC
           " X Y"
         #endif
       ));
 
       #if HAS_HEATED_BED
-        // Restore the bed temperature
-        sprintf_P(cmd, PSTR("M190 S%i"), job_recovery_info.target_temperature_bed);
-        enqueue_and_echo_command(cmd);
+        const int16_t bt = job_recovery_info.target_temperature_bed;
+        if (bt) {
+          // Restore the bed temperature
+          sprintf_P(cmd, PSTR("M190 S%i"), bt);
+          enqueue_and_echo_command(cmd);
+        }
       #endif
 
       // Restore all hotend temperatures
       HOTEND_LOOP() {
-        sprintf_P(cmd, PSTR("M109 S%i"), job_recovery_info.target_temperature[e]);
-        enqueue_and_echo_command(cmd);
+        const int16_t et = job_recovery_info.target_temperature[e];
+        if (et) {
+          #if HOTENDS > 1
+            sprintf_P(cmd, PSTR("T%i"), e);
+            enqueue_and_echo_command(cmd);
+          #endif
+          sprintf_P(cmd, PSTR("M109 S%i"), et);
+          enqueue_and_echo_command(cmd);
+        }
       }
 
+      #if HOTENDS > 1
+        sprintf_P(cmd, PSTR("T%i"), job_recovery_info.active_hotend);
+        enqueue_and_echo_command(cmd);
+      #endif
+
       // Restore print cooling fan speeds
       for (uint8_t i = 0; i < FAN_COUNT; i++) {
-        sprintf_P(cmd, PSTR("M106 P%i S%i"), i, job_recovery_info.fanSpeeds[i]);
-        enqueue_and_echo_command(cmd);
+        int16_t f = job_recovery_info.fanSpeeds[i];
+        if (f) {
+          sprintf_P(cmd, PSTR("M106 P%i S%i"), i, f);
+          enqueue_and_echo_command(cmd);
+        }
       }
 
       // Start draining the job recovery command queue
       job_recovery_phase = JOB_RECOVERY_YES;
+    }
 
-      // Resume the print job timer
-      if (job_recovery_info.print_job_elapsed)
-        print_job_timer.resume(job_recovery_info.print_job_elapsed);
-
-      // Start getting commands from SD
-      card.startFileprint();
+    static void lcd_power_loss_recovery_cancel() {
+      card.removeJobRecoveryFile();
+      card.autostart_index = 0;
+      lcd_return_to_status();
     }
 
     static void lcd_job_recovery_menu() {
       defer_return_to_status = true;
       START_MENU();
-      MENU_ITEM(function, MSG_RESUME_PRINT, lcd_sdcard_recover_job);
-      MENU_ITEM(function, MSG_STOP_PRINT, lcd_sdcard_stop);
+      STATIC_ITEM(MSG_POWER_LOSS_RECOVERY);
+      MENU_ITEM(function, MSG_RESUME_PRINT, lcd_power_loss_recovery_resume);
+      MENU_ITEM(function, MSG_STOP_PRINT, lcd_power_loss_recovery_cancel);
       END_MENU();
     }
 

Marlin/src/sd/cardreader.cpp

@@ -541,9 +541,13 @@ void CardReader::checkautostart() {
 
   if (!cardOK) initsd();
 
-  if (cardOK) {
+  if (cardOK
+    #if ENABLED(POWER_LOSS_RECOVERY)
+      && !jobRecoverFileExists() // Don't run auto#.g when a resume file exists
+    #endif
+  ) {
     char autoname[10];
-    sprintf_P(autoname, PSTR("auto%i.g"), autostart_index);
+    sprintf_P(autoname, PSTR("auto%i.g"), int(autostart_index));
     dir_t p;
     root.rewind();
     while (root.readDir(&p, NULL) > 0) {
@@ -990,20 +994,24 @@ void CardReader::printingHasFinished() {
       SERIAL_PROTOCOLCHAR('.');
       SERIAL_EOL();
     }
-    else
+    else if (!read)
       SERIAL_PROTOCOLLNPAIR(MSG_SD_WRITE_TO_FILE, job_recovery_file_name);
   }
 
   void CardReader::closeJobRecoveryFile() { jobRecoveryFile.close(); }
 
   bool CardReader::jobRecoverFileExists() {
-    return jobRecoveryFile.open(&root, job_recovery_file_name, O_READ);
+    const bool exists = jobRecoveryFile.open(&root, job_recovery_file_name, O_READ);
+    if (exists) jobRecoveryFile.close();
+    return exists;
   }
 
   int16_t CardReader::saveJobRecoveryInfo() {
     jobRecoveryFile.seekSet(0);
     const int16_t ret = jobRecoveryFile.write(&job_recovery_info, sizeof(job_recovery_info));
-    if (ret == -1) SERIAL_PROTOCOLLNPGM("Power-loss file write failed.");
+    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+      if (ret == -1) SERIAL_PROTOCOLLNPGM("Power-loss file write failed.");
+    #endif
     return ret;
   }
 
@@ -1013,13 +1021,16 @@ void CardReader::printingHasFinished() {
 
   void CardReader::removeJobRecoveryFile() {
     job_recovery_info.valid_head = job_recovery_info.valid_foot = job_recovery_commands_count = 0;
-    const bool success = jobRecoveryFile.remove(&root, job_recovery_file_name);
-    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-      SERIAL_PROTOCOLPGM("Power-loss file delete");
-      serialprintPGM(success ? PSTR("d.\n") : PSTR(" failed.\n"));
-    #else
-      UNUSED(success);
-    #endif
+    if (jobRecoverFileExists()) {
+      closefile();
+      removeFile(job_recovery_file_name);
+      #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+        SERIAL_PROTOCOLPGM("Power-loss file delete");
+        serialprintPGM(jobRecoverFileExists() ? PSTR(" failed.\n") : PSTR("d.\n"));
+      #else
+        UNUSED(success);
+      #endif
+    }
   }
 
 #endif // POWER_LOSS_RECOVERY

Marlin/src/sd/cardreader.h

@@ -142,7 +142,7 @@ public:
 public:
   bool saving, logging, sdprinting, cardOK, filenameIsDir;
   char filename[FILENAME_LENGTH], longFilename[LONG_FILENAME_LENGTH];
-  int autostart_index;
+  int8_t autostart_index;
 private:
   SdFile root, workDir, workDirParents[MAX_DIR_DEPTH];
   uint8_t workDirDepth;