Fix some Power Loss Recovery behaviors (#18558)

Marlin/src/MarlinCore.cpp

@@ -395,6 +395,13 @@ void disable_all_steppers() {
 #endif
 
 /**
+ * A Print Job exists when the timer is running or SD printing
+ */
+bool printJobOngoing() {
+  return print_job_timer.isRunning() || IS_SD_PRINTING();
+}
+
+/**
  * Printing is active when the print job timer is running
  */
 bool printingIsActive() {
@@ -690,7 +697,7 @@ void idle(TERN_(ADVANCED_PAUSE_FEATURE, bool no_stepper_sleep/*=false*/)) {
 
   // Handle Power-Loss Recovery
   #if ENABLED(POWER_LOSS_RECOVERY) && PIN_EXISTS(POWER_LOSS)
-    recovery.outage();
+    if (printJobOngoing()) recovery.outage();
   #endif
 
   // Run StallGuard endstop checks

Marlin/src/feature/powerloss.cpp

@@ -66,12 +66,16 @@ PrintJobRecovery recovery;
 #ifndef POWER_LOSS_PURGE_LEN
   #define POWER_LOSS_PURGE_LEN 0
 #endif
+#ifndef POWER_LOSS_ZRAISE
+  #define POWER_LOSS_ZRAISE 2     // Move on loss with backup power, or on resume without it
+#endif
+
+#if DISABLED(BACKUP_POWER_SUPPLY)
+  #undef POWER_LOSS_RETRACT_LEN   // No retract at outage without backup power
+#endif
 #ifndef POWER_LOSS_RETRACT_LEN
   #define POWER_LOSS_RETRACT_LEN 0
 #endif
-#ifndef POWER_LOSS_ZRAISE
-  #define POWER_LOSS_ZRAISE 2
-#endif
 
 /**
  * Clear the recovery info
@@ -144,7 +148,7 @@ void PrintJobRecovery::prepare() {
 /**
  * Save the current machine state to the power-loss recovery file
  */
-void PrintJobRecovery::save(const bool force/*=false*/) {
+void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=0*/) {
 
   #if SAVE_INFO_INTERVAL_MS > 0
     static millis_t next_save_ms; // = 0
@@ -177,6 +181,7 @@ void PrintJobRecovery::save(const bool force/*=false*/) {
 
     // Machine state
     info.current_position = current_position;
+    info.zraise = zraise;
     TERN_(HAS_HOME_OFFSET, info.home_offset = home_offset);
     TERN_(HAS_POSITION_SHIFT, info.position_shift = position_shift);
     info.feedrate = uint16_t(feedrate_mm_s * 60.0f);
@@ -228,30 +233,73 @@ void PrintJobRecovery::save(const bool force/*=false*/) {
 
 #if PIN_EXISTS(POWER_LOSS)
 
+  #if ENABLED(BACKUP_POWER_SUPPLY)
+
+    void PrintJobRecovery::retract_and_lift(const float &zraise) {
+      #if POWER_LOSS_RETRACT_LEN || POWER_LOSS_ZRAISE
+
+        gcode.set_relative_mode(true);  // Use relative coordinates
+
+        #if POWER_LOSS_RETRACT_LEN
+          // Retract filament now
+          gcode.process_subcommands_now_P(PSTR("G1 F3000 E-" STRINGIFY(POWER_LOSS_RETRACT_LEN)));
+        #endif
+
+        #if POWER_LOSS_ZRAISE
+          // Raise the Z axis now
+          if (zraise) {
+            char cmd[20], str_1[16];
+            sprintf_P(cmd, PSTR("G0 Z%s"), dtostrf(zraise, 1, 3, str_1));
+            gcode.process_subcommands_now(cmd);
+          }
+        #else
+          UNUSED(zraise);
+        #endif
+
+        //gcode.axis_relative = info.axis_relative;
+        planner.synchronize();
+      #endif
+    }
+
+  #endif
+
+  /**
+   * An outage was detected by a sensor pin.
+   *  - If not SD printing, let the machine turn off on its own with no "KILL" screen
+   *  - Disable all heaters first to save energy
+   *  - Save the recovery data for the current instant
+   *  - If backup power is available Retract E and Raise Z
+   *  - Go to the KILL screen
+   */
   void PrintJobRecovery::_outage() {
     #if ENABLED(BACKUP_POWER_SUPPLY)
       static bool lock = false;
-      if (lock) return; // No re-entrance from idle() during raise_z()
+      if (lock) return; // No re-entrance from idle() during retract_and_lift()
       lock = true;
     #endif
-    if (IS_SD_PRINTING()) save(true);
-    TERN_(BACKUP_POWER_SUPPLY, raise_z());
 
-    kill(GET_TEXT(MSG_OUTAGE_RECOVERY));
-  }
+    #if POWER_LOSS_ZRAISE
+      // Get the limited Z-raise to do now or on resume
+      const float zraise = _MAX(0, _MIN(current_position.z + POWER_LOSS_ZRAISE, Z_MAX_POS - 1) - current_position.z);
+    #else
+      constexpr float zraise = 0;
+    #endif
 
-  #if ENABLED(BACKUP_POWER_SUPPLY)
+    // Save, including the limited Z raise
+    if (IS_SD_PRINTING()) save(true, zraise);
+
+    // Disable all heaters to reduce power loss
+    thermalManager.disable_all_heaters();
 
-    void PrintJobRecovery::raise_z() {
-      // Disable all heaters to reduce power loss
-      thermalManager.disable_all_heaters();
+    #if ENABLED(BACKUP_POWER_SUPPLY)
+      // Do a hard-stop of the steppers (with possibly a loud thud)
       quickstop_stepper();
-      // Raise Z axis
-      gcode.process_subcommands_now_P(PSTR("G91\nG0 Z" STRINGIFY(POWER_LOSS_ZRAISE)));
-      planner.synchronize();
-    }
+      // With backup power a retract and raise can be done now
+      retract_and_lift(zraise);
+    #endif
 
-  #endif
+    kill(GET_TEXT(MSG_OUTAGE_RECOVERY));
+  }
 
 #endif
 
@@ -274,6 +322,8 @@ void PrintJobRecovery::write() {
  */
 void PrintJobRecovery::resume() {
 
+  char cmd[MAX_CMD_SIZE+16], str_1[16], str_2[16];
+
   const uint32_t resume_sdpos = info.sdpos; // Get here before the stepper ISR overwrites it
 
   #if HAS_LEVELING
@@ -282,52 +332,46 @@ void PrintJobRecovery::resume() {
   #endif
 
   // Reset E, raise Z, home XY...
-  gcode.process_subcommands_now_P(PSTR("G92.9 E0"
-    #if Z_HOME_DIR > 0
+  #if Z_HOME_DIR > 0
 
-      // If Z homing goes to max, just reset E and home all
-      "\n"
-      "G28R0"
-      TERN_(MARLIN_DEV_MODE, "S")
+    // If Z homing goes to max, just reset E and home all
+    gcode.process_subcommands_now_P(PSTR(
+      "G92.9 E0\n"
+      "G28R0" TERN_(MARLIN_DEV_MODE, "S")
+    ));
 
-    #else // "G92.9 E0 ..."
+  #else // "G92.9 E0 ..."
 
-      // Set Z to 0, raise Z by RECOVERY_ZRAISE, and Home (XY only for Cartesian)
-      // with no raise. (Only do simulated homing in Marlin Dev Mode.)
-      #if ENABLED(BACKUP_POWER_SUPPLY)
-        "Z" STRINGIFY(POWER_LOSS_ZRAISE)    // Z-axis was already raised at outage
-      #else
-        "Z0\n"                              // Set Z=0
-        "G1Z" STRINGIFY(POWER_LOSS_ZRAISE)  // Raise Z
-      #endif
-      "\n"
+    // Set Z to 0, raise Z by info.zraise, and Home (XY only for Cartesian)
+    // with no raise. (Only do simulated homing in Marlin Dev Mode.)
 
-      "G28R0"
-      #if ENABLED(MARLIN_DEV_MODE)
-        "S"
-      #elif !IS_KINEMATIC
-        "XY"
-      #endif
-    #endif
-  ));
-
-  // Pretend that all axes are homed
-  axis_homed = axis_known_position = xyz_bits;
+    sprintf_P(cmd, PSTR("G92.9 E0 "
+        #if ENABLED(BACKUP_POWER_SUPPLY)
+          "Z%s"                             // Z was already raised at outage
+        #else
+          "Z0\nG1Z%s"                       // Set Z=0 and Raise Z now
+        #endif
+      ),
+      dtostrf(info.zraise, 1, 3, str_1)
+    );
+    gcode.process_subcommands_now(cmd);
 
-  char cmd[MAX_CMD_SIZE+16], str_1[16], str_2[16];
+    gcode.process_subcommands_now_P(PSTR(
+      "G28R0"                               // No raise during G28
+      TERN_(MARLIN_DEV_MODE, "S")           // Simulated Homing
+      TERN_(IS_CARTESIAN, "XY")             // Don't home Z on Cartesian
+    ));
 
-  // Select the previously active tool (with no_move)
-  #if EXTRUDERS > 1
-    sprintf_P(cmd, PSTR("T%i S"), info.active_extruder);
-    gcode.process_subcommands_now(cmd);
   #endif
 
+  // Pretend that all axes are homed
+  axis_homed = axis_known_position = xyz_bits;
+
   // Recover volumetric extrusion state
   #if DISABLED(NO_VOLUMETRICS)
     #if EXTRUDERS > 1
       for (int8_t e = 0; e < EXTRUDERS; e++) {
-        dtostrf(info.filament_size[e], 1, 3, str_1);
-        sprintf_P(cmd, PSTR("M200 T%i D%s"), e, str_1);
+        sprintf_P(cmd, PSTR("M200 T%i D%s"), e, dtostrf(info.filament_size[e], 1, 3, str_1));
         gcode.process_subcommands_now(cmd);
       }
       if (!info.volumetric_enabled) {
@@ -336,8 +380,7 @@ void PrintJobRecovery::resume() {
       }
     #else
       if (info.volumetric_enabled) {
-        dtostrf(info.filament_size[0], 1, 3, str_1);
-        sprintf_P(cmd, PSTR("M200 D%s"), str_1);
+        sprintf_P(cmd, PSTR("M200 D%s"), dtostrf(info.filament_size[0], 1, 3, str_1));
         gcode.process_subcommands_now(cmd);
       }
     #endif
@@ -358,7 +401,7 @@ void PrintJobRecovery::resume() {
       const int16_t et = info.target_temperature[e];
       if (et) {
         #if HAS_MULTI_HOTEND
-          sprintf_P(cmd, PSTR("T%i"), e);
+          sprintf_P(cmd, PSTR("T%i S"), e);
           gcode.process_subcommands_now(cmd);
         #endif
         sprintf_P(cmd, PSTR("M109 S%i"), et);
@@ -367,6 +410,12 @@ void PrintJobRecovery::resume() {
     }
   #endif
 
+  // Select the previously active tool (with no_move)
+  #if EXTRUDERS > 1
+    sprintf_P(cmd, PSTR("T%i S"), info.active_extruder);
+    gcode.process_subcommands_now(cmd);
+  #endif
+
   // Restore print cooling fan speeds
   FANS_LOOP(i) {
     uint8_t f = info.fan_speed[i];
@@ -400,18 +449,21 @@ void PrintJobRecovery::resume() {
     memcpy(&mixer.gradient, &info.gradient, sizeof(info.gradient));
   #endif
 
-  // Extrude and retract to clean the nozzle
-  #if POWER_LOSS_PURGE_LEN
-    //sprintf_P(cmd, PSTR("G1 E%d F200"), POWER_LOSS_PURGE_LEN);
-    //gcode.process_subcommands_now(cmd);
-    gcode.process_subcommands_now_P(PSTR("G1 E" STRINGIFY(POWER_LOSS_PURGE_LEN) " F200"));
+  // Un-retract if there was a retract at outage
+  #if POWER_LOSS_RETRACT_LEN
+    gcode.process_subcommands_now_P(PSTR("G1 E" STRINGIFY(POWER_LOSS_RETRACT_LEN) " F3000"));
   #endif
 
-  #if POWER_LOSS_RETRACT_LEN
-    sprintf_P(cmd, PSTR("G1 E%d F3000"), POWER_LOSS_PURGE_LEN - (POWER_LOSS_RETRACT_LEN));
+  // Additional purge if configured
+  #if POWER_LOSS_PURGE_LEN
+    sprintf_P(cmd, PSTR("G1 E%d F200"), (POWER_LOSS_PURGE_LEN) + (POWER_LOSS_RETRACT_LEN));
     gcode.process_subcommands_now(cmd);
   #endif
 
+  #if ENABLED(NOZZLE_CLEAN_FEATURE)
+    gcode.process_subcommands_now_P(PSTR("G12"));
+  #endif
+
   // Move back to the saved XY
   sprintf_P(cmd, PSTR("G1 X%s Y%s F3000"),
     dtostrf(info.current_position.x, 1, 3, str_1),
@@ -429,13 +481,6 @@ void PrintJobRecovery::resume() {
   #endif
   gcode.process_subcommands_now(cmd);
 
-  // Un-retract
-  #if POWER_LOSS_PURGE_LEN
-    //sprintf_P(cmd, PSTR("G1 E%d F3000"), POWER_LOSS_PURGE_LEN);
-    //gcode.process_subcommands_now(cmd);
-    gcode.process_subcommands_now_P(PSTR("G1 E" STRINGIFY(POWER_LOSS_PURGE_LEN) " F3000"));
-  #endif
-
   // Restore the feedrate
   sprintf_P(cmd, PSTR("G1 F%d"), info.feedrate);
   gcode.process_subcommands_now(cmd);
@@ -476,6 +521,8 @@ void PrintJobRecovery::resume() {
         }
         DEBUG_EOL();
 
+        DEBUG_ECHOLNPAIR("zraise: ", info.zraise);
+
         #if HAS_HOME_OFFSET
           DEBUG_ECHOPGM("home_offset: ");
           LOOP_XYZ(i) {

Marlin/src/feature/powerloss.h

@@ -26,6 +26,8 @@
  */
 
 #include "../sd/cardreader.h"
+#include "../gcode/gcode.h"
+
 #include "../inc/MarlinConfig.h"
 
 #if ENABLED(MIXING_EXTRUDER)
@@ -45,6 +47,7 @@ typedef struct {
 
   // Machine state
   xyze_pos_t current_position;
+  float zraise;
 
   #if HAS_HOME_OFFSET
     xyz_pos_t home_offset;
@@ -161,33 +164,34 @@ class PrintJobRecovery {
     static inline void cancel() { purge(); card.autostart_index = 0; }
 
     static void load();
-    static void save(const bool force=ENABLED(SAVE_EACH_CMD_MODE));
+    static void save(const bool force=ENABLED(SAVE_EACH_CMD_MODE), const float zraise=0);
 
-  #if PIN_EXISTS(POWER_LOSS)
-    static inline void outage() {
-      if (enabled && READ(POWER_LOSS_PIN) == POWER_LOSS_STATE)
-        _outage();
-    }
-  #endif
+    #if PIN_EXISTS(POWER_LOSS)
+      static inline void outage() {
+        if (enabled && READ(POWER_LOSS_PIN) == POWER_LOSS_STATE)
+          _outage();
+      }
+    #endif
 
-  static inline bool valid() { return info.valid(); }
+    static inline bool valid() { return info.valid(); }
 
-  #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
-    static void debug(PGM_P const prefix);
-  #else
-    static inline void debug(PGM_P const) {}
-  #endif
+    #if ENABLED(DEBUG_POWER_LOSS_RECOVERY)
+      static void debug(PGM_P const prefix);
+    #else
+      static inline void debug(PGM_P const) {}
+    #endif
 
   private:
     static void write();
 
-  #if ENABLED(BACKUP_POWER_SUPPLY)
-    static void raise_z();
-  #endif
+    #if ENABLED(BACKUP_POWER_SUPPLY)
+      static void retract_and_lift(const float &zraise);
+    #endif
 
-  #if PIN_EXISTS(POWER_LOSS)
-    static void _outage();
-  #endif
+    #if PIN_EXISTS(POWER_LOSS)
+      friend class GcodeSuite;
+      static void _outage();
+    #endif
 };
 
 extern PrintJobRecovery recovery;

Marlin/src/gcode/feature/powerloss/M413.cpp

@@ -50,6 +50,9 @@ void GcodeSuite::M413() {
     if (parser.seen("RL")) recovery.load();
     if (parser.seen('W')) recovery.save(true);
     if (parser.seen('P')) recovery.purge();
+    #if PIN_EXISTS(POWER_LOSS)
+      if (parser.seen('O')) recovery._outage();
+    #endif
     if (parser.seen('E')) serialprintPGM(recovery.exists() ? PSTR("PLR Exists\n") : PSTR("No PLR\n"));
     if (parser.seen('V')) serialprintPGM(recovery.valid() ? PSTR("Valid\n") : PSTR("Invalid\n"));
   #endif

Marlin/src/lcd/language/language_en.h

@@ -363,7 +363,7 @@ namespace Language_en {
   PROGMEM Language_Str MSG_PRINTING_OBJECT                 = _UxGT("Printing Object");
   PROGMEM Language_Str MSG_CANCEL_OBJECT                   = _UxGT("Cancel Object");
   PROGMEM Language_Str MSG_CANCEL_OBJECT_N                 = _UxGT("Cancel Object =");
-  PROGMEM Language_Str MSG_OUTAGE_RECOVERY                 = _UxGT("Outage Recovery");
+  PROGMEM Language_Str MSG_OUTAGE_RECOVERY                 = _UxGT("Power Outage");
   PROGMEM Language_Str MSG_MEDIA_MENU                      = _UxGT("Print from Media");
   PROGMEM Language_Str MSG_NO_MEDIA                        = _UxGT("No Media");
   PROGMEM Language_Str MSG_DWELL                           = _UxGT("Sleep...");

Marlin/src/module/temperature.cpp

@@ -2026,33 +2026,29 @@ void Temperature::disable_all_heaters() {
 
   TERN_(AUTOTEMP, planner.autotemp_enabled = false);
 
-  #if HAS_HOTEND
-    HOTEND_LOOP() setTargetHotend(0, e);
-  #endif
-  TERN_(HAS_HEATED_BED, setTargetBed(0));
-  TERN_(HAS_HEATED_CHAMBER, setTargetChamber(0));
-
   // Unpause and reset everything
   TERN_(PROBING_HEATERS_OFF, pause(false));
 
-  #define DISABLE_HEATER(N) {           \
-    setTargetHotend(0, N);              \
-    temp_hotend[N].soft_pwm_amount = 0; \
-    WRITE_HEATER_##N(LOW);              \
-  }
+  #if HAS_HOTEND
+    HOTEND_LOOP() {
+      setTargetHotend(0, e);
+      temp_hotend[e].soft_pwm_amount = 0;
+    }
+  #endif
 
   #if HAS_TEMP_HOTEND
+    #define DISABLE_HEATER(N) WRITE_HEATER_##N(LOW)
     REPEAT(HOTENDS, DISABLE_HEATER);
   #endif
 
   #if HAS_HEATED_BED
-    temp_bed.target = 0;
+    setTargetBed(0);
     temp_bed.soft_pwm_amount = 0;
     WRITE_HEATER_BED(LOW);
   #endif
 
   #if HAS_HEATED_CHAMBER
-    temp_chamber.target = 0;
+    setTargetChamber(0);
     temp_chamber.soft_pwm_amount = 0;
     WRITE_HEATER_CHAMBER(LOW);
   #endif

Marlin/src/module/temperature.h

@@ -576,7 +576,7 @@ class Temperature {
           else if (temp_hotend[ee].target == 0)
             start_preheat_time(ee);
         #endif
-        TERN_(AUTO_POWER_CONTROL, powerManager.power_on());
+        TERN_(AUTO_POWER_CONTROL, if (celsius) powerManager.power_on());
         temp_hotend[ee].target = _MIN(celsius, temp_range[ee].maxtemp - HOTEND_OVERSHOOT);
         start_watching_hotend(ee);
       }
@@ -624,7 +624,7 @@ class Temperature {
       #endif
 
       static void setTargetBed(const int16_t celsius) {
-        TERN_(AUTO_POWER_CONTROL, powerManager.power_on());
+        TERN_(AUTO_POWER_CONTROL, if (celsius) powerManager.power_on());
         temp_bed.target =
           #ifdef BED_MAX_TARGET
             _MIN(celsius, BED_MAX_TARGET)

buildroot/tests/rambo-tests

@@ -40,6 +40,7 @@ opt_enable REPRAP_DISCOUNT_SMART_CONTROLLER LCD_PROGRESS_BAR LCD_PROGRESS_BAR_TE
            PSU_CONTROL AUTO_POWER_CONTROL POWER_LOSS_RECOVERY POWER_LOSS_PIN POWER_LOSS_STATE \
            SLOW_PWM_HEATERS THERMAL_PROTECTION_CHAMBER LIN_ADVANCE EXTRA_LIN_ADVANCE_K \
            HOST_ACTION_COMMANDS HOST_PROMPT_SUPPORT PINS_DEBUGGING MAX7219_DEBUG M114_DETAIL
+opt_add DEBUG_POWER_LOSS_RECOVERY
 exec_test $1 $2 "RAMBO | EXTRUDERS 2 | CHAR LCD + SD | FIX Probe | ABL-Linear | Advanced Pause | PLR | LEDs ..."
 
 #