ConfigGen: properly support pretuned sensorless configs, set sensorle…

…ss as default on mk3

configuration/printers/prusa-mk3s/printer-definition.json

@@ -37,8 +37,8 @@
 				"partFan": "4pin-dedicated",
 				"hotendFan": "4pin-dedicated",
 				"probe": "superpinda",
-				"xEndstop": "endstop",
-				"yEndstop": "endstop"
+				"xEndstop": "sensorless",
+				"yEndstop": "sensorless"
 			}
 		],
 		"rails": [

configuration/printers/prusa-mk3s/sensorless-homing-tmc2130.cfg

@@ -13,6 +13,9 @@ position_max: 255
 homing_speed: 25
 homing_retract_dist: 0
 
+[tmc2130 stepper_x]
+driver_SGT: 0
+
 [stepper_y]
 endstop_pin: tmc2130_stepper_y:virtual_endstop
 position_endstop: -4
@@ -21,6 +24,9 @@ position_max: 212.5
 homing_speed: 25
 homing_retract_dist: 0
 
+[tmc2130 stepper_y]
+driver_SGT: 0
+
 [stepper_z]
 endstop_pin: probe:z_virtual_endstop
 position_min: -5

src/__tests__/fixtures/prusa-mk3s.json

@@ -6,8 +6,8 @@
       "hotend": "v6",
       "thermistor": "ATC Semitec 104GT-2", 
       "extruder": "mk3s",
-      "xEndstop": "endstop",
-      "yEndstop": "endstop",
+      "xEndstop": "sensorless",
+      "yEndstop": "sensorless",
       "hotendFan": "4pin-dedicated",
       "partFan": "4pin-dedicated",
       "nozzle": {

src/__tests__/server.test.ts

@@ -55,13 +55,15 @@ const serializedConfigFromDefaults = (printer: PrinterDefinition): SerializedPri
 
 const loadConfig = async (path: string) => {
 	const config = await loadSerializedConfig(path);
-	const res: string = (await getFilesToWrite(config)).find((f) => f.fileName === 'RatOS.cfg')?.content ?? '';
+	const files = await getFilesToWrite(config);
+	const res: string = files.find((f) => f.fileName === 'RatOS.cfg')?.content ?? '';
 	const splitRes = res.split('\n');
 	const annotatedLines = splitRes.map((l: string, i: number) => `Line-${i + 1}`.padEnd(10, '-') + `|${l}`);
 	return {
 		splitRes,
 		annotatedLines,
 		config,
+		files,
 	};
 };
 
@@ -242,16 +244,16 @@ describe('server', async () => {
 				}
 			});
 		});
-		describe('can generate a config without resonance tester', async () => {
+		describe('can generate a valid mk3s config', async () => {
 			const prusaMk3sConfigPath = path.join(__dirname, 'fixtures', 'prusa-mk3s.json');
-			const { splitRes, annotatedLines, config } = await loadConfig(prusaMk3sConfigPath);
-			const gcodeBlocks: number[] = [];
-			splitRes.forEach((l, i) => l.includes('[resonance_tester]') && gcodeBlocks.push(i));
+			const { splitRes, annotatedLines, config, files } = await loadConfig(prusaMk3sConfigPath);
 			test('produces valid config', async () => {
 				expectValidConfig(config, splitRes, annotatedLines);
 			});
+			const resonanceTesterBlocks: number[] = [];
+			splitRes.forEach((l, i) => l.includes('[resonance_tester]') && resonanceTesterBlocks.push(i));
 			test('does not include resonance tester in the config', async () => {
-				for (const block of gcodeBlocks) {
+				for (const block of resonanceTesterBlocks) {
 					try {
 						expect(splitRes[block].includes('[resonance_tester]')).toBeFalsy();
 					} catch (e) {
@@ -261,6 +263,31 @@ describe('server', async () => {
 					}
 				}
 			});
+			const sensorlessBlocks: number[] = [];
+			const endstopBlocks: number[] = [];
+			splitRes.forEach((l, i) => l.includes('[include sensorless-homing') && sensorlessBlocks.push(i));
+			splitRes.forEach((l, i) => l.includes('variable_homing_x: "endstop"') && endstopBlocks.push(i));
+			splitRes.forEach((l, i) => l.includes('variable_homing_y: "endstop"') && endstopBlocks.push(i));
+			test('correctly configures sensorless homing', async () => {
+				try {
+					expect(endstopBlocks.length).toBeLessThan(1);
+				} catch (e) {
+					throw new Error(
+						`Found endstop configuration:\n${annotatedLines.slice(endstopBlocks[0] - 4, endstopBlocks[0] + 5).join('\n')}`,
+					);
+				}
+				expect(sensorlessBlocks.length).toBe(2);
+			});
+			test('correctly comments out generated sensorless defaults', async () => {
+				expect(files.find((f) => f.fileName === 'sensorless-homing-x.cfg')?.content).toContain(
+					'#variable_sensorless_x_current: ',
+				);
+				expect(files.find((f) => f.fileName === 'sensorless-homing-y.cfg')?.content).toContain(
+					'#variable_sensorless_y_current: ',
+				);
+				expect(files.find((f) => f.fileName === 'sensorless-homing-x.cfg')?.content).toContain('#driver_SGT: 0');
+				expect(files.find((f) => f.fileName === 'sensorless-homing-y.cfg')?.content).toContain('#driver_SGT: 0');
+			});
 		});
 		describe('can generate another idex config', async () => {
 			const config = await loadSerializedConfig(path.join(__dirname, 'fixtures', 'another-idex.json'));
@@ -408,8 +435,12 @@ describe('server', async () => {
 			test.concurrent('can render sensorless homing files', async () => {
 				const config = await loadSerializedConfig(path.join(__dirname, 'fixtures', 'hybrid-config.json'));
 				const utils = await constructKlipperConfigUtils(config);
-				const x = sensorlessXTemplate(config, utils);
-				const y = sensorlessYTemplate(config, utils);
+				const x = sensorlessXTemplate(config, utils, false);
+				const y = sensorlessYTemplate(config, utils, false);
+				expect(x).toContain('variable_sensorless_x_current:');
+				expect(y).toContain('variable_sensorless_y_current:');
+				expect(x).toContain('driver_SGTHRS:');
+				expect(y).toContain('driver_SGTHRS:');
 			});
 		});
 		describe('can generate v-minion config', async () => {

src/server/helpers/klipper-config.ts

@@ -222,7 +222,7 @@ export const constructKlipperConfigUtils = async (config: PrinterConfiguration)
 		getAxisDriverHomingCurrent(axis: PrinterAxis, factor: number) {
 			const rail = this.getRail(axis);
 			factor = Math.max(0, Math.min(1, factor));
-			return rail.stepper.maxPeakCurrent * 0.71 * factor;
+			return Math.round(rail.stepper.maxPeakCurrent * 0.71 * factor * 1000) / 1000;
 		},
 		getExtruderPinPrefix(tool: ToolOrAxis = 0) {
 			const th = this.getToolhead(tool);
@@ -382,19 +382,19 @@ export const constructKlipperConfigExtrasGenerator = (config: PrinterConfigurati
 				return [`[save_variables]`, `filename: ${path.join(environment.KLIPPER_CONFIG_PATH, f.fileName)}`].join('\n');
 			});
 		},
-		generateSensorlessHomingIncludes() {
+		generateSensorlessHomingIncludes(hasPretunedConfig: boolean) {
 			const filesToWrite: WritableFiles = [];
 			if (utils.isSensorless(PrinterAxis.x)) {
 				filesToWrite.push({
 					fileName: 'sensorless-homing-x.cfg',
-					content: sensorlessXTemplate(config, utils),
+					content: sensorlessXTemplate(config, utils, hasPretunedConfig),
 					overwrite: false,
 				});
 			}
 			if (utils.isSensorless(PrinterAxis.y)) {
 				filesToWrite.push({
 					fileName: 'sensorless-homing-y.cfg',
-					content: sensorlessYTemplate(config, utils),
+					content: sensorlessYTemplate(config, utils, hasPretunedConfig),
 					overwrite: false,
 				});
 			}
@@ -1009,8 +1009,9 @@ export const constructKlipperConfigHelpers = async (
 						))
 				) {
 					result.push(`[include ${pretunedSensorlessConfig}]`);
+					result.push(extrasGenerator.generateSensorlessHomingIncludes(true));
 				} else {
-					result.push(extrasGenerator.generateSensorlessHomingIncludes());
+					result.push(extrasGenerator.generateSensorlessHomingIncludes(false));
 				}
 			}
 			if (utils.getToolheads().every((th) => th.getProbe() == null)) {

src/templates/extras/sensorless-homing.ts

@@ -1,7 +1,11 @@
 import { KlipperConfigUtils } from '@/server/helpers/klipper-config';
 import { PrinterAxis } from '@/zods/motion';
 import { PrinterConfiguration } from '@/zods/printer-configuration';
-export const sensorlessXTemplate = (config: PrinterConfiguration, utils: KlipperConfigUtils) => `
+export const sensorlessXTemplate = (
+	config: PrinterConfiguration,
+	utils: KlipperConfigUtils,
+	hasPretunedConfig: boolean,
+) => `
 # Sensorless homing.
 #
 # Tune the sensorless_x_current variable and the SGTHRS/SGT value in this file untill you get reliable homing.
@@ -16,18 +20,24 @@ export const sensorlessXTemplate = (config: PrinterConfiguration, utils: Klipper
 
 [${utils.getAxisDriverSectionName(PrinterAxis.x)}]
 ${utils.getAxisDriverDiagConfig(PrinterAxis.x)}
-${utils.getAxisDriverStallGuardThreshold(PrinterAxis.x, 0.5)}
+${hasPretunedConfig ? '# Printer has a pretuned sensorless homing config, uncomment the next line to override it' : ''}
+${hasPretunedConfig ? '#' : ''}${utils.getAxisDriverStallGuardThreshold(PrinterAxis.x, 0.5)}
 
 [${utils.getAxisStepperName(PrinterAxis.x)}]
 endstop_pin: ${utils.getAxisVirtualEndstop(PrinterAxis.x)}
 homing_retract_dist: 0
 
 [gcode_macro RatOS]
 variable_homing_x: "sensorless"
-variable_sensorless_x_current: ${utils.getAxisDriverHomingCurrent(PrinterAxis.x, 0.35)}
+${hasPretunedConfig ? '# Printer has a pretuned sensorless homing config, uncomment the next line to override it' : ''}
+${hasPretunedConfig ? '#' : ''}variable_sensorless_x_current: ${utils.getAxisDriverHomingCurrent(PrinterAxis.x, 0.35)}
 `;
 
-export const sensorlessYTemplate = (config: PrinterConfiguration, utils: KlipperConfigUtils) => `
+export const sensorlessYTemplate = (
+	config: PrinterConfiguration,
+	utils: KlipperConfigUtils,
+	hasPretunedConfig: boolean,
+) => `
 # Sensorless homing.
 #
 # Tune the current variable and the SGTHRS value in the included file(s) untill you get reliable homing.
@@ -42,13 +52,15 @@ export const sensorlessYTemplate = (config: PrinterConfiguration, utils: Klipper
 
 [${utils.getAxisDriverSectionName(PrinterAxis.y)}]
 ${utils.getAxisDriverDiagConfig(PrinterAxis.y)}
-${utils.getAxisDriverStallGuardThreshold(PrinterAxis.y, 0.5)}
+${hasPretunedConfig ? '# Printer has a pretuned sensorless homing config, uncomment the next line to override it' : ''}
+${hasPretunedConfig ? '#' : ''}${utils.getAxisDriverStallGuardThreshold(PrinterAxis.y, 0.5)}
 
 [stepper_y]
 endstop_pin: ${utils.getAxisVirtualEndstop(PrinterAxis.y)}
 homing_retract_dist: 0
 
 [gcode_macro RatOS]
 variable_homing_y: "sensorless"
-variable_sensorless_y_current: ${utils.getAxisDriverHomingCurrent(PrinterAxis.y, 0.51)}
+${hasPretunedConfig ? '# Printer has a pretuned sensorless homing config, uncomment the next line to override it' : ''}
+${hasPretunedConfig ? '#' : ''}variable_sensorless_y_current: ${utils.getAxisDriverHomingCurrent(PrinterAxis.y, 0.51)}
 `;