⚡️ Optimize Planner calculations (#24484)

Marlin/src/module/planner.cpp

@@ -28,12 +28,14 @@
  * Derived from Grbl
  * Copyright (c) 2009-2011 Simen Svale Skogsrud
  *
- * The ring buffer implementation gleaned from the wiring_serial library by David A. Mellis.
+ * Ring buffer gleaned from wiring_serial library by David A. Mellis.
  *
+ * Fast inverse function needed for Bézier interpolation for AVR
+ * was designed, written and tested by Eduardo José Tagle, April 2018.
  *
- * Reasoning behind the mathematics in this module (in the key of 'Mathematica'):
+ * Planner mathematics (Mathematica-style):
  *
- * s == speed, a == acceleration, t == time, d == distance
+ * Where: s == speed, a == acceleration, t == time, d == distance
  *
  * Basic definitions:
  *   Speed[s_, a_, t_] := s + (a*t)
@@ -41,7 +43,7 @@
  *
  * Distance to reach a specific speed with a constant acceleration:
  *   Solve[{Speed[s, a, t] == m, Travel[s, a, t] == d}, d, t]
- *   d -> (m^2 - s^2)/(2 a) --> estimate_acceleration_distance()
+ *   d -> (m^2 - s^2) / (2 a)
  *
  * Speed after a given distance of travel with constant acceleration:
  *   Solve[{Speed[s, a, t] == m, Travel[s, a, t] == d}, m, t]
@@ -49,17 +51,18 @@
  *
  * DestinationSpeed[s_, a_, d_] := Sqrt[2 a d + s^2]
  *
- * When to start braking (di) to reach a specified destination speed (s2) after accelerating
- * from initial speed s1 without ever stopping at a plateau:
+ * When to start braking (di) to reach a specified destination speed (s2) after
+ * acceleration from initial speed s1 without ever reaching a plateau:
  *   Solve[{DestinationSpeed[s1, a, di] == DestinationSpeed[s2, a, d - di]}, di]
- *   di -> (2 a d - s1^2 + s2^2)/(4 a) --> intersection_distance()
+ *   di -> (2 a d - s1^2 + s2^2)/(4 a)
  *
- * IntersectionDistance[s1_, s2_, a_, d_] := (2 a d - s1^2 + s2^2)/(4 a)
+ * We note, as an optimization, that if we have already calculated an
+ * acceleration distance d1 from s1 to m and a deceration distance d2
+ * from m to s2 then
  *
- * --
- *
- * The fast inverse function needed for Bézier interpolation for AVR
- * was designed, written and tested by Eduardo José Tagle on April/2018
+ *   d1 -> (m^2 - s1^2) / (2 a)
+ *   d2 -> (m^2 - s2^2) / (2 a)
+ *   di -> (d + d1 - d2) / 2
  */
 
 #include "planner.h"
@@ -211,7 +214,7 @@ xyze_long_t Planner::position{0};
 uint32_t Planner::acceleration_long_cutoff;
 
 xyze_float_t Planner::previous_speed;
-float Planner::previous_nominal_speed_sqr;
+float Planner::previous_nominal_speed;
 
 #if ENABLED(DISABLE_INACTIVE_EXTRUDER)
   last_move_t Planner::g_uc_extruder_last_move[E_STEPPERS] = { 0 };
@@ -220,7 +223,7 @@ float Planner::previous_nominal_speed_sqr;
 #ifdef XY_FREQUENCY_LIMIT
   int8_t Planner::xy_freq_limit_hz = XY_FREQUENCY_LIMIT;
   float Planner::xy_freq_min_speed_factor = (XY_FREQUENCY_MIN_PERCENT) * 0.01f;
-  int32_t Planner::xy_freq_min_interval_us = LROUND(1000000.0 / (XY_FREQUENCY_LIMIT));
+  int32_t Planner::xy_freq_min_interval_us = LROUND(1000000.0f / (XY_FREQUENCY_LIMIT));
 #endif
 
 #if ENABLED(LIN_ADVANCE)
@@ -250,7 +253,7 @@ void Planner::init() {
   TERN_(HAS_POSITION_FLOAT, position_float.reset());
   TERN_(IS_KINEMATIC, position_cart.reset());
   previous_speed.reset();
-  previous_nominal_speed_sqr = 0;
+  previous_nominal_speed = 0;
   TERN_(ABL_PLANAR, bed_level_matrix.set_to_identity());
   clear_block_buffer();
   delay_before_delivering = 0;
@@ -786,41 +789,48 @@ void Planner::calculate_trapezoid_for_block(block_t * const block, const_float_t
   NOLESS(final_rate, uint32_t(MINIMAL_STEP_RATE));
 
   #if ENABLED(S_CURVE_ACCELERATION)
-    uint32_t cruise_rate = initial_rate;
+    // If we have some plateau time, the cruise rate will be the nominal rate
+    uint32_t cruise_rate = block->nominal_rate;
   #endif
 
   const int32_t accel = block->acceleration_steps_per_s2;
 
-          // Steps required for acceleration, deceleration to/from nominal rate
-  uint32_t accelerate_steps = CEIL(estimate_acceleration_distance(initial_rate, block->nominal_rate, accel)),
-           decelerate_steps = FLOOR(estimate_acceleration_distance(block->nominal_rate, final_rate, -accel));
-          // Steps between acceleration and deceleration, if any
-  int32_t plateau_steps = block->step_event_count - accelerate_steps - decelerate_steps;
-
-  // Does accelerate_steps + decelerate_steps exceed step_event_count?
-  // Then we can't possibly reach the nominal rate, there will be no cruising.
-  // Use intersection_distance() to calculate accel / braking time in order to
-  // reach the final_rate exactly at the end of this block.
-  if (plateau_steps < 0) {
-    const float accelerate_steps_float = CEIL(intersection_distance(initial_rate, final_rate, accel, block->step_event_count));
-    accelerate_steps = _MIN(uint32_t(_MAX(accelerate_steps_float, 0)), block->step_event_count);
-    decelerate_steps = block->step_event_count - accelerate_steps;
-    plateau_steps = 0;
-
-    #if ENABLED(S_CURVE_ACCELERATION)
-      // We won't reach the cruising rate. Let's calculate the speed we will reach
-      cruise_rate = final_speed(initial_rate, accel, accelerate_steps);
-    #endif
+  // Steps for acceleration, plateau and deceleration
+  int32_t plateau_steps = block->step_event_count;
+  uint32_t accelerate_steps = 0,
+           decelerate_steps = 0;
+
+  if (accel != 0) {
+    // Steps required for acceleration, deceleration to/from nominal rate
+    const float nominal_rate_sq = sq(float(block->nominal_rate));
+    float accelerate_steps_float = (nominal_rate_sq - sq(float(initial_rate))) * (0.5f / accel);
+    accelerate_steps = CEIL(accelerate_steps_float);
+    const float decelerate_steps_float = (nominal_rate_sq - sq(float(final_rate))) * (0.5f / accel);
+    decelerate_steps = decelerate_steps_float;
+
+    // Steps between acceleration and deceleration, if any
+    plateau_steps -= accelerate_steps + decelerate_steps;
+
+    // Does accelerate_steps + decelerate_steps exceed step_event_count?
+    // Then we can't possibly reach the nominal rate, there will be no cruising.
+    // Calculate accel / braking time in order to reach the final_rate exactly
+    // at the end of this block.
+    if (plateau_steps < 0) {
+      accelerate_steps_float = CEIL((block->step_event_count + accelerate_steps_float - decelerate_steps_float) * 0.5f);
+      accelerate_steps = _MIN(uint32_t(_MAX(accelerate_steps_float, 0)), block->step_event_count);
+      decelerate_steps = block->step_event_count - accelerate_steps;
+
+      #if ENABLED(S_CURVE_ACCELERATION)
+        // We won't reach the cruising rate. Let's calculate the speed we will reach
+        cruise_rate = final_speed(initial_rate, accel, accelerate_steps);
+      #endif
+    }
   }
-  #if ENABLED(S_CURVE_ACCELERATION)
-    else // We have some plateau time, so the cruise rate will be the nominal rate
-      cruise_rate = block->nominal_rate;
-  #endif
 
   #if ENABLED(S_CURVE_ACCELERATION)
     // Jerk controlled speed requires to express speed versus time, NOT steps
-    uint32_t acceleration_time = ((float)(cruise_rate - initial_rate) / accel) * (STEPPER_TIMER_RATE),
-             deceleration_time = ((float)(cruise_rate - final_rate) / accel) * (STEPPER_TIMER_RATE),
+    uint32_t acceleration_time = (float(cruise_rate - initial_rate) / accel) * (STEPPER_TIMER_RATE),
+             deceleration_time = (float(cruise_rate - final_rate) / accel) * (STEPPER_TIMER_RATE),
     // And to offload calculations from the ISR, we also calculate the inverse of those times here
              acceleration_time_inverse = get_period_inverse(acceleration_time),
              deceleration_time_inverse = get_period_inverse(deceleration_time);
@@ -1175,7 +1185,7 @@ void Planner::recalculate_trapezoids(TERN_(HINTS_SAFE_EXIT_SPEED, const_float_t
 
   // Go from the tail (currently executed block) to the first block, without including it)
   block_t *block = nullptr, *next = nullptr;
-  float current_entry_speed = 0.0, next_entry_speed = 0.0;
+  float current_entry_speed = 0.0f, next_entry_speed = 0.0f;
   while (block_index != head_block_index) {
 
     next = &block_buffer[block_index];
@@ -1199,13 +1209,12 @@ void Planner::recalculate_trapezoids(TERN_(HINTS_SAFE_EXIT_SPEED, const_float_t
             // Block is not BUSY, we won the race against the Stepper ISR:
 
             // NOTE: Entry and exit factors always > 0 by all previous logic operations.
-            const float current_nominal_speed = SQRT(block->nominal_speed_sqr),
-                        nomr = 1.0f / current_nominal_speed;
+            const float nomr = 1.0f / block->nominal_speed;
             calculate_trapezoid_for_block(block, current_entry_speed * nomr, next_entry_speed * nomr);
             #if ENABLED(LIN_ADVANCE)
               if (block->use_advance_lead) {
                 const float comp = block->e_D_ratio * extruder_advance_K[active_extruder] * settings.axis_steps_per_mm[E_AXIS];
-                block->max_adv_steps = current_nominal_speed * comp;
+                block->max_adv_steps = block->nominal_speed * comp;
                 block->final_adv_steps = next_entry_speed * comp;
               }
             #endif
@@ -1240,13 +1249,12 @@ void Planner::recalculate_trapezoids(TERN_(HINTS_SAFE_EXIT_SPEED, const_float_t
     if (!stepper.is_block_busy(block)) {
       // Block is not BUSY, we won the race against the Stepper ISR:
 
-      const float current_nominal_speed = SQRT(block->nominal_speed_sqr),
-                  nomr = 1.0f / current_nominal_speed;
+      const float nomr = 1.0f / block->nominal_speed;
       calculate_trapezoid_for_block(block, current_entry_speed * nomr, next_entry_speed * nomr);
       #if ENABLED(LIN_ADVANCE)
         if (block->use_advance_lead) {
           const float comp = block->e_D_ratio * extruder_advance_K[active_extruder] * settings.axis_steps_per_mm[E_AXIS];
-          block->max_adv_steps = current_nominal_speed * comp;
+          block->max_adv_steps = block->nominal_speed * comp;
           block->final_adv_steps = next_entry_speed * comp;
         }
       #endif
@@ -1290,14 +1298,10 @@ void Planner::recalculate(TERN_(HINTS_SAFE_EXIT_SPEED, const_float_t safe_exit_s
     #define FAN_SET(F) do{ kickstart_fan(fan_speed, ms, F); _FAN_SET(F); }while(0)
 
     const millis_t ms = millis();
-    TERN_(HAS_FAN0, FAN_SET(0));
-    TERN_(HAS_FAN1, FAN_SET(1));
-    TERN_(HAS_FAN2, FAN_SET(2));
-    TERN_(HAS_FAN3, FAN_SET(3));
-    TERN_(HAS_FAN4, FAN_SET(4));
-    TERN_(HAS_FAN5, FAN_SET(5));
-    TERN_(HAS_FAN6, FAN_SET(6));
-    TERN_(HAS_FAN7, FAN_SET(7));
+    TERN_(HAS_FAN0, FAN_SET(0)); TERN_(HAS_FAN1, FAN_SET(1));
+    TERN_(HAS_FAN2, FAN_SET(2)); TERN_(HAS_FAN3, FAN_SET(3));
+    TERN_(HAS_FAN4, FAN_SET(4)); TERN_(HAS_FAN5, FAN_SET(5));
+    TERN_(HAS_FAN6, FAN_SET(6)); TERN_(HAS_FAN7, FAN_SET(7));
   }
 
   #if FAN_KICKSTART_TIME
@@ -1485,7 +1489,7 @@ void Planner::check_axes_activity() {
     for (uint8_t b = block_buffer_tail; b != block_buffer_head; b = next_block_index(b)) {
       const block_t * const block = &block_buffer[b];
       if (NUM_AXIS_GANG(block->steps.x, || block->steps.y, || block->steps.z, || block->steps.i, || block->steps.j, || block->steps.k, || block->steps.u, || block->steps.v, || block->steps.w)) {
-        const float se = (float)block->steps.e / block->step_event_count * SQRT(block->nominal_speed_sqr); // mm/sec;
+        const float se = float(block->steps.e) / block->step_event_count * block->nominal_speed; // mm/sec
         NOLESS(high, se);
       }
     }
@@ -1936,7 +1940,7 @@ bool Planner::_populate_block(
           #if ENABLED(MIXING_EXTRUDER)
             bool ignore_e = false;
             float collector[MIXING_STEPPERS];
-            mixer.refresh_collector(1.0, mixer.get_current_vtool(), collector);
+            mixer.refresh_collector(1.0f, mixer.get_current_vtool(), collector);
             MIXER_STEPPER_LOOP(e)
               if (e_steps * collector[e] > max_e_steps) { ignore_e = true; break; }
           #else
@@ -2193,7 +2197,7 @@ bool Planner::_populate_block(
       #if SECONDARY_LINEAR_AXES >= 1 && NONE(FOAMCUTTER_XYUV, ARTICULATED_ROBOT_ARM)
         if (NEAR_ZERO(distance_sqr)) {
           // Move does not involve any primary linear axes (xyz) but might involve secondary linear axes
-          distance_sqr = (0.0
+          distance_sqr = (0.0f
             SECONDARY_AXIS_GANG(
               IF_DISABLED(AXIS4_ROTATES, + sq(steps_dist_mm.i)),
               IF_DISABLED(AXIS5_ROTATES, + sq(steps_dist_mm.j)),
@@ -2396,7 +2400,7 @@ bool Planner::_populate_block(
     if (was_enabled) stepper.wake_up();
   #endif
 
-  block->nominal_speed_sqr = sq(block->millimeters * inverse_secs);   // (mm/sec)^2 Always > 0
+  block->nominal_speed = block->millimeters * inverse_secs;           // (mm/sec) Always > 0
   block->nominal_rate = CEIL(block->step_event_count * inverse_secs); // (step/sec) Always > 0
 
   #if ENABLED(FILAMENT_WIDTH_SENSOR)
@@ -2492,7 +2496,7 @@ bool Planner::_populate_block(
   if (speed_factor < 1.0f) {
     current_speed *= speed_factor;
     block->nominal_rate *= speed_factor;
-    block->nominal_speed_sqr = block->nominal_speed_sqr * sq(speed_factor);
+    block->nominal_speed *= speed_factor;
   }
 
   // Compute and limit the acceleration rate for the trapezoid generator.
@@ -2592,7 +2596,7 @@ bool Planner::_populate_block(
     if (block->use_advance_lead) {
       block->advance_speed = (STEPPER_TIMER_RATE) / (extruder_advance_K[active_extruder] * block->e_D_ratio * block->acceleration * settings.axis_steps_per_mm[E_AXIS_N(extruder)]);
       #if ENABLED(LA_DEBUG)
-        if (extruder_advance_K[active_extruder] * block->e_D_ratio * block->acceleration * 2 < SQRT(block->nominal_speed_sqr) * block->e_D_ratio)
+        if (extruder_advance_K[active_extruder] * block->e_D_ratio * block->acceleration * 2 < block->nominal_speed * block->e_D_ratio)
           SERIAL_ECHOLNPGM("More than 2 steps per eISR loop executed.");
         if (block->advance_speed < 200)
           SERIAL_ECHOLNPGM("eISR running at > 10kHz.");
@@ -2663,7 +2667,7 @@ bool Planner::_populate_block(
       unit_vec *= inverse_millimeters;      // Use pre-calculated (1 / SQRT(x^2 + y^2 + z^2))
 
     // Skip first block or when previous_nominal_speed is used as a flag for homing and offset cycles.
-    if (moves_queued && !UNEAR_ZERO(previous_nominal_speed_sqr)) {
+    if (moves_queued && !UNEAR_ZERO(previous_nominal_speed)) {
       // Compute cosine of angle between previous and current path. (prev_unit_vec is negative)
       // NOTE: Max junction velocity is computed without sin() or acos() by trig half angle identity.
       float junction_cos_theta = LOGICAL_AXIS_GANG(
@@ -2792,7 +2796,7 @@ bool Planner::_populate_block(
       }
 
       // Get the lowest speed
-      vmax_junction_sqr = _MIN(vmax_junction_sqr, block->nominal_speed_sqr, previous_nominal_speed_sqr);
+      vmax_junction_sqr = _MIN(vmax_junction_sqr, sq(block->nominal_speed), sq(previous_nominal_speed));
     }
     else // Init entry speed to zero. Assume it starts from rest. Planner will correct this later.
       vmax_junction_sqr = 0;
@@ -2801,27 +2805,17 @@ bool Planner::_populate_block(
 
   #endif
 
-  #ifdef USE_CACHED_SQRT
-    #define CACHED_SQRT(N, V) \
-      static float saved_V, N; \
-      if (V != saved_V) { N = SQRT(V); saved_V = V; }
-  #else
-    #define CACHED_SQRT(N, V) const float N = SQRT(V)
-  #endif
-
   #if HAS_CLASSIC_JERK
 
     /**
      * Adapted from Průša MKS firmware
      * https://github.com/prusa3d/Prusa-Firmware
      */
-    CACHED_SQRT(nominal_speed, block->nominal_speed_sqr);
-
     // Exit speed limited by a jerk to full halt of a previous last segment
     static float previous_safe_speed;
 
     // Start with a safe speed (from which the machine may halt to stop immediately).
-    float safe_speed = nominal_speed;
+    float safe_speed = block->nominal_speed;
 
     #ifndef TRAVEL_EXTRA_XYJERK
       #define TRAVEL_EXTRA_XYJERK 0
@@ -2834,7 +2828,7 @@ bool Planner::_populate_block(
                   maxj = (max_jerk[i] + (i == X_AXIS || i == Y_AXIS ? extra_xyjerk : 0.0f)); // mj : The max jerk setting for this axis
       if (jerk > maxj) {                          // cs > mj : New current speed too fast?
         if (limited) {                            // limited already?
-          const float mjerk = nominal_speed * maxj; // ns*mj
+          const float mjerk = block->nominal_speed * maxj; // ns*mj
           if (jerk * safe_speed > mjerk) safe_speed = mjerk / jerk; // ns*mj/cs
         }
         else {
@@ -2845,7 +2839,7 @@ bool Planner::_populate_block(
     }
 
     float vmax_junction;
-    if (moves_queued && !UNEAR_ZERO(previous_nominal_speed_sqr)) {
+    if (moves_queued && !UNEAR_ZERO(previous_nominal_speed)) {
       // Estimate a maximum velocity allowed at a joint of two successive segments.
       // If this maximum velocity allowed is lower than the minimum of the entry / exit safe velocities,
       // then the machine is not coasting anymore and the safe entry / exit velocities shall be used.
@@ -2856,11 +2850,9 @@ bool Planner::_populate_block(
 
       // The junction velocity will be shared between successive segments. Limit the junction velocity to their minimum.
       // Pick the smaller of the nominal speeds. Higher speed shall not be achieved at the junction during coasting.
-      CACHED_SQRT(previous_nominal_speed, previous_nominal_speed_sqr);
-
       float smaller_speed_factor = 1.0f;
-      if (nominal_speed < previous_nominal_speed) {
-        vmax_junction = nominal_speed;
+      if (block->nominal_speed < previous_nominal_speed) {
+        vmax_junction = block->nominal_speed;
         smaller_speed_factor = vmax_junction / previous_nominal_speed;
       }
       else
@@ -2927,11 +2919,11 @@ bool Planner::_populate_block(
   // block nominal speed limits both the current and next maximum junction speeds. Hence, in both
   // the reverse and forward planners, the corresponding block junction speed will always be at the
   // the maximum junction speed and may always be ignored for any speed reduction checks.
-  block->flag.set_nominal(block->nominal_speed_sqr <= v_allowable_sqr);
+  block->flag.set_nominal(sq(block->nominal_speed) <= v_allowable_sqr);
 
   // Update previous path unit_vector and nominal speed
   previous_speed = current_speed;
-  previous_nominal_speed_sqr = block->nominal_speed_sqr;
+  previous_nominal_speed = block->nominal_speed;
 
   position = target;  // Update the position
 
@@ -3268,7 +3260,7 @@ void Planner::set_machine_position_mm(const abce_pos_t &abce) {
   );
 
   if (has_blocks_queued()) {
-    //previous_nominal_speed_sqr = 0.0; // Reset planner junction speeds. Assume start from rest.
+    //previous_nominal_speed = 0.0f; // Reset planner junction speeds. Assume start from rest.
     //previous_speed.reset();
     buffer_sync_block(BLOCK_BIT_SYNC_POSITION);
   }
@@ -3344,7 +3336,7 @@ void Planner::refresh_positioning() {
 inline void limit_and_warn(float &val, const AxisEnum axis, PGM_P const setting_name, const xyze_float_t &max_limit) {
   const uint8_t lim_axis = TERN_(HAS_EXTRUDERS, axis > E_AXIS ? E_AXIS :) axis;
   const float before = val;
-  LIMIT(val, 0.1, max_limit[lim_axis]);
+  LIMIT(val, 0.1f, max_limit[lim_axis]);
   if (before != val) {
     SERIAL_CHAR(AXIS_CHAR(lim_axis));
     SERIAL_ECHOPGM(" Max ");

Marlin/src/module/planner.h

@@ -199,7 +199,7 @@ typedef struct PlannerBlock {
   volatile bool is_move() { return !(is_sync() || is_page()); }
 
   // Fields used by the motion planner to manage acceleration
-  float nominal_speed_sqr,                  // The nominal speed for this block in (mm/sec)^2
+  float nominal_speed,                      // The nominal speed for this block in (mm/sec)
         entry_speed_sqr,                    // Entry speed at previous-current junction in (mm/sec)^2
         max_entry_speed_sqr,                // Maximum allowable junction entry speed in (mm/sec)^2
         millimeters,                        // The total travel of this block in mm
@@ -510,7 +510,7 @@ class Planner {
     /**
      * Nominal speed of previous path line segment (mm/s)^2
      */
-    static float previous_nominal_speed_sqr;
+    static float previous_nominal_speed;
 
     /**
      * Limit where 64bit math is necessary for acceleration calculation
@@ -1010,28 +1010,6 @@ class Planner {
     static constexpr uint8_t prev_block_index(const uint8_t block_index) { return BLOCK_MOD(block_index - 1); }
 
     /**
-     * Calculate the distance (not time) it takes to accelerate
-     * from initial_rate to target_rate using the given acceleration:
-     */
-    static float estimate_acceleration_distance(const_float_t initial_rate, const_float_t target_rate, const_float_t accel) {
-      if (accel == 0) return 0; // accel was 0, set acceleration distance to 0
-      return (sq(target_rate) - sq(initial_rate)) / (accel * 2);
-    }
-
-    /**
-     * Return the point at which you must start braking (at the rate of -'accel') if
-     * you start at 'initial_rate', accelerate (until reaching the point), and want to end at
-     * 'final_rate' after traveling 'distance'.
-     *
-     * This is used to compute the intersection point between acceleration and deceleration
-     * in cases where the "trapezoid" has no plateau (i.e., never reaches maximum speed)
-     */
-    static float intersection_distance(const_float_t initial_rate, const_float_t final_rate, const_float_t accel, const_float_t distance) {
-      if (accel == 0) return 0; // accel was 0, set intersection distance to 0
-      return (accel * 2 * distance - sq(initial_rate) + sq(final_rate)) / (accel * 4);
-    }
-
-    /**
      * Calculate the maximum allowable speed squared at this point, in order
      * to reach 'target_velocity_sqr' using 'acceleration' within a given
      * 'distance'.