Fix and improve Power-Loss Recovery (#21779)

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

Marlin/src/feature/pause.cpp

   // Save current position
   resume_position = current_position;
 
+  // Will the nozzle be parking?
+  const bool do_park = !axes_should_home();
+
+  #if ENABLED(POWER_LOSS_RECOVERY)
+    // Save PLR info in case the power goes out while parked
+    const float park_raise = do_park ? nozzle.park_mode_0_height(park_point.z) - current_position.z : POWER_LOSS_ZRAISE;
+    if (was_sd_printing && recovery.enabled) recovery.save(true, park_raise, do_park);
+  #endif
+
   // Wait for buffered blocks to complete
   planner.synchronize();
 
     unscaled_e_move(retract, PAUSE_PARK_RETRACT_FEEDRATE);
   }
 
-  // Park the nozzle by doing a Minimum Z Raise followed by an XY Move
-  if (!axes_should_home())
-    nozzle.park(0, park_point);
+  // If axes don't need to home then the nozzle can park
+  if (do_park) nozzle.park(0, park_point); // Park the nozzle by doing a Minimum Z Raise followed by an XY Move
 
   #if ENABLED(DUAL_X_CARRIAGE)
     const int8_t saved_ext        = active_extruder;
     set_duplication_enabled(false, DXC_ext);
   #endif
 
-  if (unload_length)   // Unload the filament
+  // Unload the filament, if specified
+  if (unload_length)
     unload_filament(unload_length, show_lcd, PAUSE_MODE_CHANGE_FILAMENT);
 
   #if ENABLED(DUAL_X_CARRIAGE)

Marlin/src/feature/powerloss.cpp

 /**
  * Save the current machine state to the power-loss recovery file
  */
-void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=0*/) {
+void PrintJobRecovery::save(const bool force/*=false*/, const float zraise/*=POWER_LOSS_ZRAISE*/, const bool raised/*=false*/) {
 
   // We don't check IS_SD_PRINTING here so a save may occur during a pause
 
     info.current_position = current_position;
     info.feedrate = uint16_t(MMS_TO_MMM(feedrate_mm_s));
     info.zraise = zraise;
+    info.flag.raised = raised;                      // Was Z raised before power-off?
 
     TERN_(GCODE_REPEAT_MARKERS, info.stored_repeat = repeat);
     TERN_(HAS_HOME_OFFSET, info.home_offset = home_offset);
     TERN_(HAS_POSITION_SHIFT, info.position_shift = position_shift);
-
-    #if HAS_MULTI_EXTRUDER
-      info.active_extruder = active_extruder;
-    #endif
+    TERN_(HAS_MULTI_EXTRUDER, info.active_extruder = active_extruder);
 
     #if DISABLED(NO_VOLUMETRICS)
       info.flag.volumetric_enabled = parser.volumetric_enabled;
       constexpr float zraise = 0;
     #endif
 
-    // Save, including the limited Z raise
-    if (IS_SD_PRINTING()) save(true, zraise);
+    // Save the current position, distance that Z was (or should be) raised,
+    // and a flag whether the raise was already done here.
+    if (IS_SD_PRINTING()) save(true, zraise, ENABLED(BACKUP_POWER_SUPPLY));
 
     // Disable all heaters to reduce power loss
     thermalManager.disable_all_heaters();
     }
   #endif
 
-  // Restore all hotend temperatures
+  // Heat hotend enough to soften material
   #if HAS_HOTEND
     HOTEND_LOOP() {
-      const celsius_t et = info.target_temperature[e];
+      const celsius_t et = _MAX(info.target_temperature[e], 180);
       if (et) {
         #if HAS_MULTI_HOTEND
           sprintf_P(cmd, PSTR("T%iS"), e);
     }
   #endif
 
+  // Interpret the saved Z according to flags
+  const float z_print = info.current_position.z,
+              z_raised = z_print + info.zraise;
+
   //
   // Home the axes that can safely be homed, and
   // establish the current position as best we can.
   //
+
+  gcode.process_subcommands_now_P(PSTR("G92.9E0")); // Reset E to 0
+
   #if Z_HOME_DIR > 0
 
-    // If Z homing goes to max...
+    float z_now = z_raised;
+
+    // If Z homing goes to max then just move back to the "raised" position
     gcode.process_subcommands_now_P(PSTR(
-      "G92.9 E0\n"                          // Reset E to 0
-      "G28R0"                               // Home all axes (no raise)
-    ));
+        "G28R0\n"     // Home all axes (no raise)
+        "G1Z%sF1200"  // Move Z down to (raised) height
+      ),
+      dtostrf(z_now, 1, 3, str_1)
+    );
 
   #else
 
-    // If a Z raise occurred at outage restore Z, otherwise raise Z now
-    sprintf_P(cmd, PSTR("G92.9 E0 " TERN(BACKUP_POWER_SUPPLY, "Z%s", "Z0\nG1Z%s")), dtostrf(info.zraise, 1, 3, str_1));
-    gcode.process_subcommands_now(cmd);
+    #if ENABLED(POWER_LOSS_RECOVER_ZHOME) && defined(POWER_LOSS_ZHOME_POS)
+      #define HOMING_Z_DOWN 1
+    #else
+      #define HOME_XY_ONLY 1
+    #endif
 
-    // Home safely with no Z raise
-    gcode.process_subcommands_now_P(PSTR(
-      "G28R0"                               // No raise during G28
-      #if IS_CARTESIAN && (DISABLED(POWER_LOSS_RECOVER_ZHOME) || defined(POWER_LOSS_ZHOME_POS))
-        "XY"                                // Don't home Z on Cartesian unless overridden
-      #endif
-    ));
+    float z_now = info.flag.raised ? z_raised : z_print;
+
+    // Reset E to 0 and set Z to the real position
+    #if HOME_XY_ONLY
+      sprintf_P(cmd, PSTR("G92.9Z%s"), dtostrf(z_now, 1, 3, str_1));
+      gcode.process_subcommands_now(cmd);
+    #endif
+
+    // Does Z need to be raised now? It should be raised before homing XY.
+    if (z_raised > z_now) {
+      z_now = z_raised;
+      sprintf_P(cmd, PSTR("G1Z%sF600"), dtostrf(z_now, 1, 3, str_1));
+      gcode.process_subcommands_now(cmd);
+    }
+
+    // Home XY with no Z raise, and also home Z here if Z isn't homing down below.
+    gcode.process_subcommands_now_P(PSTR("G28R0" TERN_(HOME_XY_ONLY, "XY"))); // No raise during G28
 
   #endif
 
-  #if ENABLED(POWER_LOSS_RECOVER_ZHOME) && defined(POWER_LOSS_ZHOME_POS)
-    // Move to a safe XY position where Z can home while avoiding the print.
-    // If Z_SAFE_HOMING is enabled, its position must also be outside the print area!
+  #if HOMING_Z_DOWN
+    // Move to a safe XY position and home Z while avoiding the print.
     constexpr xy_pos_t p = POWER_LOSS_ZHOME_POS;
     sprintf_P(cmd, PSTR("G1X%sY%sF1000\nG28Z"), dtostrf(p.x, 1, 3, str_1), dtostrf(p.y, 1, 3, str_2));
     gcode.process_subcommands_now(cmd);
   // Mark all axes as having been homed (no effect on current_position)
   set_all_homed();
 
+  #if HAS_LEVELING
+    // Restore Z fade and possibly re-enable bed leveling compensation.
+    // Leveling may already be enabled due to the ENABLE_LEVELING_AFTER_G28 option.
+    // TODO: Add a G28 parameter to leave leveling disabled.
+    sprintf_P(cmd, PSTR("M420S%cZ%s"), '0' + (char)info.flag.leveling, dtostrf(info.fade, 1, 1, str_1));
+    gcode.process_subcommands_now(cmd);
+
+    #if HOME_XY_ONLY
+      // The physical Z was adjusted at power-off so undo the M420S1 correction to Z with G92.9.
+      sprintf_P(cmd, PSTR("G92.9Z%s"), dtostrf(z_now, 1, 1, str_1));
+      gcode.process_subcommands_now(cmd);
+    #endif
+  #endif
+
   #if ENABLED(POWER_LOSS_RECOVER_ZHOME)
-    // Z was homed. Now move Z back up to the saved Z height, plus the POWER_LOSS_ZRAISE.
-    sprintf_P(cmd, PSTR("G1Z%sF500"), dtostrf(info.current_position.z + POWER_LOSS_ZRAISE, 1, 3, str_1));
+    // Z was homed down to the bed, so move up to the raised height.
+    z_now = z_raised;
+    sprintf_P(cmd, PSTR("G1Z%sF600"), dtostrf(z_now, 1, 3, str_1));
     gcode.process_subcommands_now(cmd);
   #endif
 
     #endif
   #endif
 
-  // Select the previously active tool (with no_move)
-  #if HAS_MULTI_EXTRUDER
+  // Restore all hotend temperatures
+  #if HAS_HOTEND
+    HOTEND_LOOP() {
+      const celsius_t et = info.target_temperature[e];
+      if (et) {
+        #if HAS_MULTI_HOTEND
+          sprintf_P(cmd, PSTR("T%iS"), e);
+          gcode.process_subcommands_now(cmd);
+        #endif
+        sprintf_P(cmd, PSTR("M109S%i"), et);
+        gcode.process_subcommands_now(cmd);
+      }
+    }
+  #endif
+
+  // Restore the previously active tool (with no_move)
+  #if HAS_MULTI_EXTRUDER || HAS_MULTI_HOTEND
     sprintf_P(cmd, PSTR("T%i S"), info.active_extruder);
     gcode.process_subcommands_now(cmd);
   #endif
     fwretract.current_hop = info.retract_hop;
   #endif
 
-  #if HAS_LEVELING
-    // Restore leveling state before 'G92 Z' to ensure
-    // the Z stepper count corresponds to the native Z.
-    if (info.fade || info.flag.leveling) {
-      sprintf_P(cmd, PSTR("M420S%cZ%s"), '0' + (char)info.flag.leveling, dtostrf(info.fade, 1, 1, str_1));
-      gcode.process_subcommands_now(cmd);
-    }
-  #endif
-
   #if ENABLED(GRADIENT_MIX)
     memcpy(&mixer.gradient, &info.gradient, sizeof(info.gradient));
   #endif
   );
   gcode.process_subcommands_now(cmd);
 
-  // Move back to the saved Z
-  dtostrf(info.current_position.z, 1, 3, str_1);
-  #if Z_HOME_DIR > 0 || ENABLED(POWER_LOSS_RECOVER_ZHOME)
-    sprintf_P(cmd, PSTR("G1 Z%s F500"), str_1);
-  #else
-    gcode.process_subcommands_now_P(PSTR("G1 Z0 F200"));
-    sprintf_P(cmd, PSTR("G92.9 Z%s"), str_1);
-  #endif
+  // Move back down to the saved Z for printing
+  sprintf_P(cmd, PSTR("G1Z%sF600"), dtostrf(z_print, 1, 3, str_1));
   gcode.process_subcommands_now(cmd);
 
   // Restore the feedrate
         }
         DEBUG_EOL();
 
-        DEBUG_ECHOLNPAIR("zraise: ", info.zraise);
+        DEBUG_ECHOLNPAIR("feedrate: ", info.feedrate);
+
+        DEBUG_ECHOLNPAIR("zraise: ", info.zraise, " ", info.flag.raised ? "(before)" : "");
+
+        #if ENABLED(GCODE_REPEAT_MARKERS)
+          DEBUG_ECHOLNPAIR("repeat index: ", info.stored_repeat.index);
+          LOOP_L_N(i, info.stored_repeat.index)
+            DEBUG_ECHOLNPAIR("..... sdpos: ", info.stored_repeat.marker.sdpos, " count: ", info.stored_repeat.marker.counter);
+        #endif
 
         #if HAS_HOME_OFFSET
           DEBUG_ECHOPGM("home_offset: ");
           DEBUG_EOL();
         #endif
 
-        DEBUG_ECHOLNPAIR("feedrate: ", info.feedrate);
-
         #if HAS_MULTI_EXTRUDER
           DEBUG_ECHOLNPAIR("active_extruder: ", info.active_extruder);
         #endif
 
+        #if DISABLED(NO_VOLUMETRICS)
+          DEBUG_ECHOPGM("filament_size:");
+          LOOP_L_N(i, EXTRUDERS) DEBUG_ECHOLNPAIR(" ", info.filament_size[i]);
+          DEBUG_EOL();
+        #endif
+
         #if HAS_HOTEND
           DEBUG_ECHOPGM("target_temperature: ");
           HOTEND_LOOP() {
         #endif
 
         #if HAS_LEVELING
-          DEBUG_ECHOLNPAIR("leveling: ", info.flag.leveling, " fade: ", info.fade);
+          DEBUG_ECHOLNPAIR("leveling: ", info.flag.leveling ? "ON" : "OFF", "  fade: ", info.fade);
         #endif
+
         #if ENABLED(FWRETRACT)
           DEBUG_ECHOPGM("retract: ");
           for (int8_t e = 0; e < EXTRUDERS; e++) {
           DEBUG_EOL();
           DEBUG_ECHOLNPAIR("retract_hop: ", info.retract_hop);
         #endif
+
+        // Mixing extruder and gradient
+        #if BOTH(MIXING_EXTRUDER, GRADIENT_MIX)
+          DEBUG_ECHOLNPAIR("gradient: ", info.gradient.enabled ? "ON" : "OFF");
+        #endif
+
         DEBUG_ECHOLNPAIR("sd_filename: ", info.sd_filename);
         DEBUG_ECHOLNPAIR("sdpos: ", info.sdpos);
         DEBUG_ECHOLNPAIR("print_job_elapsed: ", info.print_job_elapsed);
-        DEBUG_ECHOLNPAIR("dryrun: ", AS_DIGIT(info.flag.dryrun));
-        DEBUG_ECHOLNPAIR("allow_cold_extrusion: ", info.flag.allow_cold_extrusion);
+
+        DEBUG_ECHOPGM("axis_relative:");
+        if (TEST(info.axis_relative, REL_X)) DEBUG_ECHOPGM(" REL_X");
+        if (TEST(info.axis_relative, REL_Y)) DEBUG_ECHOPGM(" REL_Y");
+        if (TEST(info.axis_relative, REL_Z)) DEBUG_ECHOPGM(" REL_Z");
+        if (TEST(info.axis_relative, REL_E)) DEBUG_ECHOPGM(" REL_E");
+        if (TEST(info.axis_relative, E_MODE_ABS)) DEBUG_ECHOPGM(" E_MODE_ABS");
+        if (TEST(info.axis_relative, E_MODE_REL)) DEBUG_ECHOPGM(" E_MODE_REL");
+        DEBUG_EOL();
+
+        DEBUG_ECHOLNPAIR("flag.dryrun: ", AS_DIGIT(info.flag.dryrun));
+        DEBUG_ECHOLNPAIR("flag.allow_cold_extrusion: ", AS_DIGIT(info.flag.allow_cold_extrusion));
+        DEBUG_ECHOLNPAIR("flag.volumetric_enabled: ", AS_DIGIT(info.flag.volumetric_enabled));
       }
       else
         DEBUG_ECHOLNPGM("INVALID DATA");

Marlin/src/feature/powerloss.h

 
   // Misc. Marlin flags
   struct {
+    bool raised:1;                // Raised before saved
     bool dryrun:1;                // M111 S8
     bool allow_cold_extrusion:1;  // M302 P1
     #if ENABLED(HAS_LEVELING)
     static inline void cancel() { purge(); IF_DISABLED(NO_SD_AUTOSTART, card.autofile_begin()); }
 
     static void load();
-    static void save(const bool force=ENABLED(SAVE_EACH_CMD_MODE), const float zraise=0);
+    static void save(const bool force=ENABLED(SAVE_EACH_CMD_MODE), const float zraise=POWER_LOSS_ZRAISE, const bool raised=false);
 
     #if PIN_EXISTS(POWER_LOSS)
       static inline void outage() {

Marlin/src/gcode/feature/pause/M125.cpp

   // If possible, show an LCD prompt with the 'P' flag
   const bool show_lcd = TERN0(HAS_LCD_MENU, parser.boolval('P'));
 
-  TERN_(POWER_LOSS_RECOVERY, if (recovery.enabled) recovery.save(true));
-
   if (pause_print(retract, park_point, show_lcd, 0)) {
     if (ENABLED(EXTENSIBLE_UI) || BOTH(EMERGENCY_PARSER, HOST_PROMPT_SUPPORT) || !sd_printing || show_lcd) {
       wait_for_confirmation(false, 0);

Marlin/src/gcode/sd/M24_M25.cpp

       if (IS_SD_PRINTING()) card.pauseSDPrint();
     #endif
 
-    #if ENABLED(POWER_LOSS_RECOVERY)
+    #if ENABLED(POWER_LOSS_RECOVERY) && DISABLED(DGUS_LCD_UI_MKS)
       if (recovery.enabled) recovery.save(true);
     #endif
 

Marlin/src/inc/SanityCheck.h

     #error "POWER_LOSS_RECOVER_ZHOME cannot be used with Z_SAFE_HOMING."
   #elif BOTH(POWER_LOSS_PULLUP, POWER_LOSS_PULLDOWN)
     #error "You can't enable POWER_LOSS_PULLUP and POWER_LOSS_PULLDOWN at the same time."
+  #elif ENABLED(POWER_LOSS_RECOVER_ZHOME) && Z_HOME_DIR > 0
+    #error "POWER_LOSS_RECOVER_ZHOME is not needed on a machine that homes to ZMAX."
   #elif BOTH(IS_CARTESIAN, POWER_LOSS_RECOVER_ZHOME) && Z_HOME_DIR < 0 && !defined(POWER_LOSS_ZHOME_POS)
     #error "POWER_LOSS_RECOVER_ZHOME requires POWER_LOSS_ZHOME_POS for a Cartesian that homes to ZMIN."
   #endif

Marlin/src/lcd/extui/dgus/mks/DGUSDisplayDef.cpp

   #include "../../../../module/stepper/trinamic.h"
 #endif
 
+#if ENABLED(POWER_LOSS_RECOVERY)
+  #include "../../../../../feature/powerloss.h"
+#endif
+
 #if ENABLED(DGUS_UI_MOVE_DIS_OPTION)
   uint16_t distanceToMove = 10;
 #endif
 void MKS_pause_print_move() {
   queue.exhaust();
   position_before_pause = current_position;
+
+  // Save the current position, the raise amount, and 'already raised'
+  TERN_(POWER_LOSS_RECOVERY, if (recovery.enabled) recovery.save(true, mks_park_pos.z, true));
+
   destination.z = _MIN(current_position.z + mks_park_pos.z, Z_MAX_POS);
   prepare_internal_move_to_destination(park_speed_z);
+
   destination.set(X_MIN_POS + mks_park_pos.x, Y_MIN_POS + mks_park_pos.y);
   prepare_internal_move_to_destination(park_speed_xy);
 }
   prepare_internal_move_to_destination(park_speed_xy);
   destination.z = position_before_pause.z;
   prepare_internal_move_to_destination(park_speed_z);
+  TERN_(POWER_LOSS_RECOVERY, if (recovery.enabled) recovery.save(true));
 }
 
 float z_offset_add = 0;

buildroot/tests/rambo

         EXTRUDERS 2 TEMP_SENSOR_0 -2 TEMP_SENSOR_1 1 TEMP_SENSOR_BED 2 \
         TEMP_SENSOR_PROBE 1 TEMP_PROBE_PIN 12 \
         TEMP_SENSOR_CHAMBER 3 TEMP_CHAMBER_PIN 3 HEATER_CHAMBER_PIN 45 \
-        Z_HOME_DIR 1 GRID_MAX_POINTS_X 16 \
+        GRID_MAX_POINTS_X 16 \
         FANMUX0_PIN 53
-opt_disable USE_ZMIN_PLUG Z_MIN_PROBE_USES_Z_MIN_ENDSTOP_PIN USE_WATCHDOG
+opt_disable Z_MIN_PROBE_USES_Z_MIN_ENDSTOP_PIN USE_WATCHDOG
 opt_enable USE_ZMAX_PLUG REPRAP_DISCOUNT_SMART_CONTROLLER LCD_PROGRESS_BAR LCD_PROGRESS_BAR_TEST \
            FIX_MOUNTED_PROBE CODEPENDENT_XY_HOMING PIDTEMPBED PROBE_TEMP_COMPENSATION \
            PREHEAT_BEFORE_PROBING PROBING_HEATERS_OFF PROBING_FANS_OFF PROBING_STEPPERS_OFF WAIT_FOR_BED_HEATER \
            SKEW_CORRECTION SKEW_CORRECTION_FOR_Z SKEW_CORRECTION_GCODE \
            BACKLASH_COMPENSATION BACKLASH_GCODE BAUD_RATE_GCODE BEZIER_CURVE_SUPPORT \
            FWRETRACT ARC_P_CIRCLES CNC_WORKSPACE_PLANES CNC_COORDINATE_SYSTEMS \
-           PSU_CONTROL AUTO_POWER_CONTROL POWER_LOSS_RECOVERY POWER_LOSS_PIN POWER_LOSS_STATE POWER_LOSS_RECOVER_ZHOME \
+           PSU_CONTROL AUTO_POWER_CONTROL POWER_LOSS_RECOVERY POWER_LOSS_PIN POWER_LOSS_STATE POWER_LOSS_RECOVER_ZHOME POWER_LOSS_ZHOME_POS \
            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
 #
 restore_configs
 opt_set MOTHERBOARD BOARD_RAMBO \
-        EXTRUDERS 0 TEMP_SENSOR_0 999 DUMMY_THERMISTOR_999_VALUE 170 \
+        EXTRUDERS 0 TEMP_SENSOR_0 999 DUMMY_THERMISTOR_999_VALUE 170 Z_HOME_DIR 1 \
         DIGIPOT_MOTOR_CURRENT '{ 120, 120, 120, 120, 120 }' \
         LEVEL_CORNERS_LEVELING_ORDER '{ LF, RF }'
 opt_enable USE_XMAX_PLUG USE_YMAX_PLUG USE_ZMAX_PLUG \