Filament Runout handling for Mixing Extruder (#20327)

Co-authored-by: Scott Lahteine <thinkyhead@users.noreply.github.com>

Marlin/Configuration.h

@@ -1278,6 +1278,8 @@
   #define FIL_RUNOUT_STATE     LOW        // Pin state indicating that filament is NOT present.
   #define FIL_RUNOUT_PULLUP               // Use internal pullup for filament runout pins.
   //#define FIL_RUNOUT_PULLDOWN           // Use internal pulldown for filament runout pins.
+  //#define WATCH_ALL_RUNOUT_SENSORS      // Execute runout script on any triggering sensor, not only for the active extruder.
+                                          // This is automatically enabled for MIXING_EXTRUDERs.
 
   // Override individually if the runout sensors vary
   //#define FIL_RUNOUT1_STATE LOW
@@ -1312,8 +1314,9 @@
   //#define FIL_RUNOUT8_PULLUP
   //#define FIL_RUNOUT8_PULLDOWN
 
-  // Set one or more commands to execute on filament runout.
-  // (After 'M412 H' Marlin will ask the host to handle the process.)
+  // Commands to execute on filament runout.
+  // With multiple runout sensors use the %c placeholder for the current tool in commands (e.g., "M600 T%c")
+  // NOTE: After 'M412 H1' the host handles filament runout and this script does not apply.
   #define FILAMENT_RUNOUT_SCRIPT "M600"
 
   // After a runout is detected, continue printing this length of filament

Marlin/src/feature/runout.cpp

@@ -47,12 +47,12 @@ bool FilamentMonitorBase::enabled = true,
 
 #if HAS_FILAMENT_RUNOUT_DISTANCE
   float RunoutResponseDelayed::runout_distance_mm = FILAMENT_RUNOUT_DISTANCE_MM;
-  volatile float RunoutResponseDelayed::runout_mm_countdown[EXTRUDERS];
+  volatile float RunoutResponseDelayed::runout_mm_countdown[NUM_RUNOUT_SENSORS];
   #if ENABLED(FILAMENT_MOTION_SENSOR)
     uint8_t FilamentSensorEncoder::motion_detected;
   #endif
 #else
-  int8_t RunoutResponseDebounced::runout_count; // = 0
+  int8_t RunoutResponseDebounced::runout_count[NUM_RUNOUT_SENSORS]; // = 0
 #endif
 
 //
@@ -70,7 +70,7 @@ bool FilamentMonitorBase::enabled = true,
   #include "../lcd/extui/ui_api.h"
 #endif
 
-void event_filament_runout() {
+void event_filament_runout(const uint8_t extruder) {
 
   if (did_pause_print) return;  // Action already in progress. Purge triggered repeated runout.
 
@@ -85,10 +85,10 @@ void event_filament_runout() {
     }
   #endif
 
-  TERN_(EXTENSIBLE_UI, ExtUI::onFilamentRunout(ExtUI::getActiveTool()));
+  TERN_(EXTENSIBLE_UI, ExtUI::onFilamentRunout(ExtUI::getTool(extruder)));
 
-  #if EITHER(HOST_PROMPT_SUPPORT, HOST_ACTION_COMMANDS)
-    const char tool = '0' + TERN0(MULTI_FILAMENT_SENSOR, active_extruder);
+  #if ANY(HOST_PROMPT_SUPPORT, HOST_ACTION_COMMANDS, MULTI_FILAMENT_SENSOR)
+    const char tool = '0' + TERN0(MULTI_FILAMENT_SENSOR, extruder);
   #endif
 
   //action:out_of_filament
@@ -124,8 +124,22 @@ void event_filament_runout() {
     SERIAL_EOL();
   #endif // HOST_ACTION_COMMANDS
 
-  if (run_runout_script)
+  if (run_runout_script) {
+    #if MULTI_FILAMENT_SENSOR
+      char script[strlen(FILAMENT_RUNOUT_SCRIPT) + 1];
+      sprintf_P(script, PSTR(FILAMENT_RUNOUT_SCRIPT), tool);
+      #if ENABLED(FILAMENT_RUNOUT_SENSOR_DEBUG)
+        SERIAL_ECHOLNPAIR("Runout Command: ", script);
+      #endif
+      queue.inject(script);
+    #else
+      #if ENABLED(FILAMENT_RUNOUT_SENSOR_DEBUG)
+        SERIAL_ECHOPGM("Runout Command: ");
+        SERIAL_ECHOLNPGM(FILAMENT_RUNOUT_SCRIPT);
+      #endif
       queue.inject_P(PSTR(FILAMENT_RUNOUT_SCRIPT));
+    #endif
+  }
 }
 
 #endif // HAS_FILAMENT_SENSOR

Marlin/src/feature/runout.h

@@ -43,7 +43,7 @@
   #define FILAMENT_RUNOUT_THRESHOLD 5
 #endif
 
-void event_filament_runout();
+void event_filament_runout(const uint8_t extruder);
 
 template<class RESPONSE_T, class SENSOR_T>
 class TFilamentMonitor;
@@ -119,11 +119,41 @@ class TFilamentMonitor : public FilamentMonitorBase {
         TERN_(HAS_FILAMENT_RUNOUT_DISTANCE, cli()); // Prevent RunoutResponseDelayed::block_completed from accumulating here
         response.run();
         sensor.run();
-        const bool ran_out = response.has_run_out();
+        const uint8_t runout_flags = response.has_run_out();
         TERN_(HAS_FILAMENT_RUNOUT_DISTANCE, sei());
+        #if MULTI_FILAMENT_SENSOR
+          #if ENABLED(WATCH_ALL_RUNOUT_SENSORS)
+            const bool ran_out = !!runout_flags;  // any sensor triggers
+            uint8_t extruder = 0;
+            if (ran_out) {
+              uint8_t bitmask = runout_flags;
+              while (!(bitmask & 1)) {
+                bitmask >>= 1;
+                extruder++;
+              }
+            }
+          #else
+            const bool ran_out = TEST(runout_flags, active_extruder);  // suppress non active extruders
+            uint8_t extruder = active_extruder;
+          #endif
+        #else
+          const bool ran_out = !!runout_flags;
+          uint8_t extruder = active_extruder;
+        #endif
+
+        #if ENABLED(FILAMENT_RUNOUT_SENSOR_DEBUG)
+          if (runout_flags) {
+            SERIAL_ECHOPGM("Runout Sensors: ");
+            LOOP_L_N(i, 8) SERIAL_ECHO('0' + TEST(runout_flags, i));
+            SERIAL_ECHOPAIR(" -> ", extruder);
+            if (ran_out) SERIAL_ECHOPGM(" RUN OUT");
+            SERIAL_EOL();
+          }
+        #endif
+
         if (ran_out) {
           filament_ran_out = true;
-          event_filament_runout();
+          event_filament_runout(extruder);
           planner.synchronize();
         }
       }
@@ -280,17 +310,18 @@ class FilamentSensorBase {
       static inline void block_completed(const block_t* const) {}
 
       static inline void run() {
-        const bool out = poll_runout_state(active_extruder);
-        if (!out) filament_present(active_extruder);
+        LOOP_L_N(s, NUM_RUNOUT_SENSORS) {
+          const bool out = poll_runout_state(s);
+          if (!out) filament_present(s);
           #if ENABLED(FILAMENT_RUNOUT_SENSOR_DEBUG)
-          static bool was_out = false;
-          if (out != was_out) {
-            was_out = out;
-            SERIAL_ECHOPGM("Filament ");
-            SERIAL_ECHOPGM_P(out ? PSTR("OUT\n") : PSTR("IN\n"));
+            static uint8_t was_out; // = 0
+            if (out != TEST(was_out, s)) {
+              TBI(was_out, s);
+              SERIAL_ECHOLNPAIR_P(PSTR("Filament Sensor "), '0' + s, out ? PSTR(" OUT") : PSTR(" IN"));
             }
           #endif
         }
+      }
   };
 
 
@@ -305,13 +336,13 @@ class FilamentSensorBase {
   // during a runout condition.
   class RunoutResponseDelayed {
     private:
-      static volatile float runout_mm_countdown[EXTRUDERS];
+      static volatile float runout_mm_countdown[NUM_RUNOUT_SENSORS];
 
     public:
       static float runout_distance_mm;
 
       static inline void reset() {
-        LOOP_L_N(i, EXTRUDERS) filament_present(i);
+        LOOP_L_N(i, NUM_RUNOUT_SENSORS) filament_present(i);
       }
 
       static inline void run() {
@@ -320,15 +351,17 @@ class FilamentSensorBase {
           const millis_t ms = millis();
           if (ELAPSED(ms, t)) {
             t = millis() + 1000UL;
-            LOOP_L_N(i, EXTRUDERS)
+            LOOP_L_N(i, NUM_RUNOUT_SENSORS)
               SERIAL_ECHOPAIR_P(i ? PSTR(", ") : PSTR("Remaining mm: "), runout_mm_countdown[i]);
             SERIAL_EOL();
           }
         #endif
       }
 
-      static inline bool has_run_out() {
-        return runout_mm_countdown[active_extruder] < 0;
+      static inline uint8_t has_run_out() {
+        uint8_t runout_flags = 0;
+        LOOP_L_N(i, NUM_RUNOUT_SENSORS) if (runout_mm_countdown[i] < 0) SBI(runout_flags, i);
+        return runout_flags;
       }
 
       static inline void filament_present(const uint8_t extruder) {
@@ -353,13 +386,28 @@ class FilamentSensorBase {
   class RunoutResponseDebounced {
     private:
       static constexpr int8_t runout_threshold = FILAMENT_RUNOUT_THRESHOLD;
-      static int8_t runout_count;
+      static int8_t runout_count[NUM_RUNOUT_SENSORS];
+
     public:
-      static inline void reset()                                  { runout_count = runout_threshold; }
-      static inline void run()                                    { if (runout_count >= 0) runout_count--; }
-      static inline bool has_run_out()                            { return runout_count < 0; }
+      static inline void reset() {
+        LOOP_L_N(i, NUM_RUNOUT_SENSORS) filament_present(i);
+      }
+
+      static inline void run() {
+        LOOP_L_N(i, NUM_RUNOUT_SENSORS) if (runout_count[i] >= 0) runout_count[i]--;
+      }
+
+      static inline uint8_t has_run_out() {
+        uint8_t runout_flags = 0;
+        LOOP_L_N(i, NUM_RUNOUT_SENSORS) if (runout_count[i] < 0) SBI(runout_flags, i);
+        return runout_flags;
+      }
+
       static inline void block_completed(const block_t* const) { }
-      static inline void filament_present(const uint8_t)          { runout_count = runout_threshold; }
+
+      static inline void filament_present(const uint8_t extruder) {
+        runout_count[extruder] = runout_threshold;
+      }
   };
 
 #endif // !HAS_FILAMENT_RUNOUT_DISTANCE

Marlin/src/inc/Conditionals_adv.h

@@ -134,6 +134,9 @@
   #ifdef FILAMENT_RUNOUT_DISTANCE_MM
     #define HAS_FILAMENT_RUNOUT_DISTANCE 1
   #endif
+  #if ENABLED(MIXING_EXTRUDER)
+    #define WATCH_ALL_RUNOUT_SENSORS
+  #endif
 #endif
 
 // Let SD_FINISHED_RELEASECOMMAND stand in for SD_FINISHED_STEPPERRELEASE

Marlin/src/inc/SanityCheck.h

@@ -823,26 +823,24 @@ static_assert(Y_MAX_LENGTH >= Y_BED_SIZE, "Movement bounds (Y_MIN_POS, Y_MAX_POS
 #if HAS_FILAMENT_SENSOR
   #if !PIN_EXISTS(FIL_RUNOUT)
     #error "FILAMENT_RUNOUT_SENSOR requires FIL_RUNOUT_PIN."
-  #elif NUM_RUNOUT_SENSORS > E_STEPPERS
-    #if HAS_PRUSA_MMU2
+  #elif HAS_PRUSA_MMU2 && NUM_RUNOUT_SENSORS != 1
       #error "NUM_RUNOUT_SENSORS must be 1 with MMU2 / MMU2S."
-    #else
-      #error "NUM_RUNOUT_SENSORS cannot exceed the number of E steppers."
-    #endif
-  #elif NUM_RUNOUT_SENSORS >= 2 && !PIN_EXISTS(FIL_RUNOUT2)
-    #error "FIL_RUNOUT2_PIN is required with NUM_RUNOUT_SENSORS >= 2."
-  #elif NUM_RUNOUT_SENSORS >= 3 && !PIN_EXISTS(FIL_RUNOUT3)
-    #error "FIL_RUNOUT3_PIN is required with NUM_RUNOUT_SENSORS >= 3."
-  #elif NUM_RUNOUT_SENSORS >= 4 && !PIN_EXISTS(FIL_RUNOUT4)
-    #error "FIL_RUNOUT4_PIN is required with NUM_RUNOUT_SENSORS >= 4."
-  #elif NUM_RUNOUT_SENSORS >= 5 && !PIN_EXISTS(FIL_RUNOUT5)
-    #error "FIL_RUNOUT5_PIN is required with NUM_RUNOUT_SENSORS >= 5."
-  #elif NUM_RUNOUT_SENSORS >= 6 && !PIN_EXISTS(FIL_RUNOUT6)
-    #error "FIL_RUNOUT6_PIN is required with NUM_RUNOUT_SENSORS >= 6."
-  #elif NUM_RUNOUT_SENSORS >= 7 && !PIN_EXISTS(FIL_RUNOUT7)
-    #error "FIL_RUNOUT7_PIN is required with NUM_RUNOUT_SENSORS >= 7."
+  #elif NUM_RUNOUT_SENSORS != 1 && NUM_RUNOUT_SENSORS != E_STEPPERS
+    #error "NUM_RUNOUT_SENSORS must be either 1 or number of E steppers."
   #elif NUM_RUNOUT_SENSORS >= 8 && !PIN_EXISTS(FIL_RUNOUT8)
     #error "FIL_RUNOUT8_PIN is required with NUM_RUNOUT_SENSORS >= 8."
+  #elif NUM_RUNOUT_SENSORS >= 7 && !PIN_EXISTS(FIL_RUNOUT7)
+    #error "FIL_RUNOUT7_PIN is required with NUM_RUNOUT_SENSORS >= 7."
+  #elif NUM_RUNOUT_SENSORS >= 6 && !PIN_EXISTS(FIL_RUNOUT6)
+    #error "FIL_RUNOUT6_PIN is required with NUM_RUNOUT_SENSORS >= 6."
+  #elif NUM_RUNOUT_SENSORS >= 5 && !PIN_EXISTS(FIL_RUNOUT5)
+    #error "FIL_RUNOUT5_PIN is required with NUM_RUNOUT_SENSORS >= 5."
+  #elif NUM_RUNOUT_SENSORS >= 4 && !PIN_EXISTS(FIL_RUNOUT4)
+    #error "FIL_RUNOUT4_PIN is required with NUM_RUNOUT_SENSORS >= 4."
+  #elif NUM_RUNOUT_SENSORS >= 3 && !PIN_EXISTS(FIL_RUNOUT3)
+    #error "FIL_RUNOUT3_PIN is required with NUM_RUNOUT_SENSORS >= 3."
+  #elif NUM_RUNOUT_SENSORS >= 2 && !PIN_EXISTS(FIL_RUNOUT2)
+    #error "FIL_RUNOUT2_PIN is required with NUM_RUNOUT_SENSORS >= 2."
   #elif BOTH(FIL_RUNOUT1_PULLUP, FIL_RUNOUT1_PULLDOWN)
     #error "You can't enable FIL_RUNOUT1_PULLUP and FIL_RUNOUT1_PULLDOWN at the same time."
   #elif BOTH(FIL_RUNOUT2_PULLUP, FIL_RUNOUT2_PULLDOWN)

Marlin/src/module/endstops.cpp

@@ -468,10 +468,7 @@ void _O2 Endstops::report_states() {
   #if HAS_CUSTOM_PROBE_PIN
     print_es_state(PROBE_TRIGGERED(), PSTR(STR_Z_PROBE));
   #endif
-  #if HAS_FILAMENT_SENSOR
-    #if NUM_RUNOUT_SENSORS == 1
-      print_es_state(READ(FIL_RUNOUT1_PIN) != FIL_RUNOUT1_STATE, PSTR(STR_FILAMENT_RUNOUT_SENSOR));
-    #else
+  #if MULTI_FILAMENT_SENSOR
     #define _CASE_RUNOUT(N) case N: pin = FIL_RUNOUT##N##_PIN; state = FIL_RUNOUT##N##_STATE; break;
     LOOP_S_LE_N(i, 1, NUM_RUNOUT_SENSORS) {
       pin_t pin;
@@ -485,7 +482,8 @@ void _O2 Endstops::report_states() {
       print_es_state(extDigitalRead(pin) != state);
     }
     #undef _CASE_RUNOUT
-    #endif
+  #elif HAS_FILAMENT_SENSOR
+    print_es_state(READ(FIL_RUNOUT1_PIN) != FIL_RUNOUT1_STATE, PSTR(STR_FILAMENT_RUNOUT_SENSOR));
   #endif
 
   TERN_(BLTOUCH, bltouch._reset_SW_mode());

buildroot/tests/mega2560-tests

@@ -94,8 +94,14 @@ restore_configs
 opt_set MOTHERBOARD BOARD_AZTEEG_X3_PRO
 opt_set LCD_LANGUAGE el_gr
 opt_enable MIXING_EXTRUDER GRADIENT_MIX GRADIENT_VTOOL CR10_STOCKDISPLAY \
-           USE_CONTROLLER_FAN CONTROLLER_FAN_EDITABLE CONTROLLER_FAN_IGNORE_Z
+           USE_CONTROLLER_FAN CONTROLLER_FAN_EDITABLE CONTROLLER_FAN_IGNORE_Z \
+           FILAMENT_RUNOUT_SENSOR ADVANCED_PAUSE_FEATURE NOZZLE_PARK_FEATURE
 opt_set MIXING_STEPPERS 5
+opt_set NUM_RUNOUT_SENSORS E_STEPPERS
+opt_set FIL_RUNOUT2_PIN 16
+opt_set FIL_RUNOUT3_PIN 17
+opt_set FIL_RUNOUT4_PIN  4
+opt_set FIL_RUNOUT5_PIN  5
 opt_set LCD_LANGUAGE ru
 exec_test $1 $2 "Azteeg X3 | Mixing Extruder (x5) | Gradient Mix | Greek" "$3"