carousel.comp

component carousel """Orient a toolchanger carousel using various encoding schemes

.B loadrt carousel pockets=\\fIN\\fR[,\\fIN\\fR]
.B encoding=\\fIssss\\fR[,\\fIsss\\fR]\\fB
.B num_sense=\\fIN\\fR[,\\fIN\\fR]
.B dir=\\fIN\\fR[,\\fIN]

.RS 4
.TP
\\fBpockets\\fR The number of pockets in each toolchanger.
Use up to 8 numbers separated by commas to create multiple carousel components.
.TP
\\fBencoding\\fR The position encoding.
gray, binary, bcd, index, edge, counts or single. Default = 'gray'
.TP
\\fBnum_sense\\fR The number of position sense pins.
Default = 4.
.TP
\\fBdir\\fR Set to 1 for unidirectional or  2 for bidirectional operation.
Default = bidirectional
.TP
\\fBparity\\fR Set to 1 for odd parity, 0 for even parity checking.
Default = 0 (even)
.RE""";

description """This component is intended to help operate various types of
carousel-type toolchangers. 

The component can be configured to operate with binary, binary-coded decimal (BCD)
or gray-coded position feedback ('binary;, 'bcd' and 'gray' modes)
It can alternatively work with an individual sensor for each tool position
('single' mode) or with a sensor at each tool position and a separate index
('index' mode). Systems using a stepper motor or quadrature encoder are
also supported ('counts' mode).
\\fBedge\\fR is a special case of index mode for tool
changers with pockets on both the rising and falling edges of the position sensor.
(Seen on at least one Denford Orac.)

Both unidirectional and bidirectional systems are supported and those that reverse
against a stop when in position. 

The number of carousel component instances created depends on the number of
entries in the 'pockets' modparam. For example

.B loadrt carousel pockets=10,10,8

Would create 3 carousel instances with 10, 10 and 8 pockets. The other 
parameters are optional. If absent then defaults will be used. Any missing
entry will assume the previous value.

When the enable pin is set to true the component will immediately set the 
"active" pin to true and then (for a bidirectional instance) calculate the
shortest path to the requested pocket number. The appropriate motor direction
output pins will then be set. Bit outputs for forward and reverse are provided
as well as a three-state velocity output for driving a DC motor PWM or a
velocity-mode stepgen.

The component will monitor the carousel position and, when the correct position
is reached, set the motor-control pins to 0, set "active" to 0 and set "ready"
to 1.

In 'index', 'edge' or 'counts'mode there is a need to find the initial
home position of the carousel.
The first time that the "enable" pin is set; the carousel will rotate forwards
searching for a home signal. In 'index' and 'edge' mode this is when
both the index and pulse inputs are true. In 'counts' mode only the index
input needs to be set to set home. Additionally in 'counts' mode the usual index-enable
logic of the encoder counters is supported.

With some carousel designs the carousel will not stop immediately. To allow for
this set the \\fBlign-dc\\fR pin to a low velocity to be used for a final latching move, and
set the\\fBdecel-time\\fR to a suitable value.
Once the decel-time has expired the carousel will, if it was moving forwards, reverse back on
to the position marker, off of the arker and then bak on to the FWD edge. If moving in reverse
it will continue off the marker and then reverse slowly on to the FWD edge.
This algnment is only possible with a motor-vel controlled bidirectional carousel,
Other combinations will be acepted but probably won't have the desired behaviour.
Some tuning will be needed of align-dc and decel-time to achieve reliable operation.

In the unusual case that the index and pulse signals do not align it is
possible to use HAL logic to achieve the desired pin switching during homing.

Setting "enable" low does not halt the homing move, so if
homing on first tool change is not needed then the enable pin can be toggled by
an axis homing pin or a script and the homing process will continue even if that
driving signal resets during the carousel homing move.

To operate the component with an encoder or stepgen use mode "C". The \\fBscale\\fR
pin should be the number of steps or encoder counts between pocket centres. The
\\fBwidth\\fR pin can be used to stop the motor some distance before the centre of
the pocket to allow the motor time to decelerate.
In mode "C" it is possible to use either the speed/direction control used in other
modes or to use direct position mode using the counts-target pin. The
internal scaling of the encoder or stepgen should be set to 1.0. A PID
hal component will be needed for encoder applications whereas stepgen
configurations can use a stepgen in position control mode or in velocity
control mode with a PID.

For tool changers which lock the carousel against a stop the \\fBrev-pulse\\fR pin can
be set to a non-zero value. The motor-rev pin will then be set for this many seconds
at the completion of the tool search and at the same time the reverse duty/cycle
velocity value will be sent to the motor-vel pin.
""";

pin in  signed pocket-number """The pocket to move to when the .enable pin goes high. If the value
passed is higher than the number of pockets specified in the "pockets" modparam then modulo arithmetic
is used. This is intended to allow the use of multiple tools in the same holder, as is sometimes
useful with lathes.""";
pin in  bit    enable "Set this pin high to start movement. Setting it low will stop movement";
pin out bit    active "indicates that the component is active";
pin out bit    ready "This pin goes high when the carousel is in-position";
pin in  bit    strobe = 1 """Use this pin to indicate that the position feedback is valid. Often
provided by binary encoders""";
pin  in bit    parity_ """Some encoders supply a parity bit, if this is connected then the
parity-error output bit will indicate parity errors""";
pin in  bit    sense-# [32:personality] """Carousel position feedback pins. In 'index' mode there 
will be only 2 pins. sense-0 is the index and sense-1 is the pocket sensor.""";
pin in float rev-pulse """The duration in seconds for which a ratchet changer (Boxford, Emco)
should pulse the reverse pin to lock the holder""";
pin in float fwd-dc "Velocity or duty cycle when forwards rotation is desired";
pin in float rev-dc "Velocity or duty cycle when reverse rotation is desired";
pin in float hold-dc "Duty cycle when carousel is in-position (to hold against stop)";
pin in float align-dc """Use this pin to set the speed of a slower alignment move once the changer is in position. Such a system almost
certainly needs decel-time setting too""";
pin in float decel-time "Time to wait for carousel to stop before final alignment and position check";
pin in signed counts "Connect to the rawcounts of an encoder or a stepgen in 'counts' mode";
pin in signed scale = 100 "The number of stepgen or encoder counts between successive pockets";
pin in signed width = 10   "How far each side of the exact scale to signal a new pocket";
pin in signed home-offset = 0 "The offset (in counts) between the index and pocket 1";
pin io bit index-enable "Used to home to an encoder index";
pin in  bit    jog-fwd "Jog the carousel forwards one tool position";
pin in  bit    jog-rev """Jog the carousel in reverse (only if dir = 2).
It is very important that these pins should be debounced and should probably
also be interlocked to only operate when the machine is idle.""";
pin out bit    motor-fwd "Indicates the motor should run forwards (bigger numbers)";
pin out bit    motor-rev "Indicates the motor should run reverse.";
pin out bit    parity-error "Indicates a parity error";
pin out signed current-position "This pin indicates the current position feedback";
pin out float  motor-vel "The duty-cycle or velocity to drive a DC motor or stepgen";
pin out bit    homed = 0 "Shows that homing is complete. Only used in index and edge modes";
pin in  bit    unhome = 0 "Should only really be necessary for testing";
pin out float counts-target "Target position for a stepgen or external PID controller";

param r  signed state = 0 "Current component state";
param r  bit    homing  = 0 "Shows that homing is in progress. Only used for index mode";
param r  float  timer "Shows the value of the internal timer";
param r signed motor-dir "Internal tag for search direction";
param r signed counts-offset "Internal offset of index pin";
param rw unsigned debounce "How many thread cycles to wait for the position to stabilise";
param r signed target "Current target pocket, debug";

option count_function;
option extra_setup;

license "GPL";
author "Andy Pugh";

variable int inst_sense;
variable int inst_dir;
variable int inst_pockets;
variable int inst_code;
variable int inst_parity;
variable int old_index = 0;
param r signed base_counts = 0;
variable int old_unhome = 0;
function _ ;

include "rtapi_math.h";

;;

int default_pockets = 8;
int default_code = 'G';
int default_dir = 2;
int default_sense = 4;
int default_parity = 0;

static bool err_once = 0;

#define MAX_CHAN 8
static int pockets[MAX_CHAN] = {-1};
RTAPI_MP_ARRAY_INT(pockets, MAX_CHAN, "The number of pockets in each carousel")
static char *encoding[MAX_CHAN];
RTAPI_MP_ARRAY_STRING(encoding, MAX_CHAN, "Position feedback type")
static int dir[MAX_CHAN] = {-1};
RTAPI_MP_ARRAY_INT(dir, MAX_CHAN, 
                    "set to 2 if the carousel is bidirectional")
static int num_sense[MAX_CHAN] = {-1};
RTAPI_MP_ARRAY_INT(num_sense, MAX_CHAN, "The number of sense pins to create")
// We have a hal pin and a modparam with the same name. From the user
// point of view I think that makes sense. In the code parity[] is the modparam,
// parity_ is the hal pin.
static int parity[MAX_CHAN] = {-1};
RTAPI_MP_ARRAY_INT(parity, MAX_CHAN, "0 for even parity, 1 for odd")

FUNCTION(_){
    int i, d, pow;
    static int deb = 0;
    int pcalc = 0;
    int mod_pocket = 0;
    int new_pos = 0;
    unsigned int mask;
    int align_pin = 0; // used for slow align move, input depends on mode for historical reasons

    switch inst_code{
    case 'G': // Gray Code
        align_pin = strobe;
        for (i = 0; i < inst_sense ; i++) {
            new_pos += sense(i) << i;
        pcalc ^= sense(i);
        }
        for(mask = new_pos >> 1 ; mask != 0 ; mask = mask >> 1){
            new_pos ^= mask;
        }
        if (new_pos == 0) new_pos = inst_pockets; // all zeros != pocket zero
        break;
    case 'B': // Straight Binary
        align_pin = strobe;
        for (i = 0; i < inst_sense ; i++) {
            new_pos += sense(i) << i;
        pcalc ^= sense(i);
        }
        break;
    case 'D': // BCD
        align_pin = strobe;
        i = 0;
        pow = 1;
        while (i < inst_sense){
            int lim;
            d = 0;
            for (lim = i + 4; i < lim && i < inst_sense; i++) {
                d += sense(i) << (i % 4);
                pcalc ^= sense(i);
            }
            new_pos += d * pow;
            pow *= 10;
        }
        break;
    case 'S': // individual sensors
        for (i = inst_sense - 1; sense(i) == 0 && i > 0 ; i--) {}
        if (sense(i)) {
            new_pos = i + 1;
        }
        align_pin = sense(current_position - 1);
        break;
    case 'I': // index + position.
        align_pin = sense(1);
        new_pos = current_position;
        if (homed && (state == 2 || state == 20)){ // Ignore transitions during home, align etc
            if ( !old_index && sense(1) ){
                if (motor_fwd){
                    new_pos += 1;
                    if (new_pos > inst_pockets) new_pos -= inst_pockets;
                }
                if (motor_rev) {
                    new_pos -= 1;
                    if (new_pos < 1) new_pos += inst_pockets;
                }
            }
            old_index = sense(1);
        }
        break;
    case 'E': // index + position, both edges.
        align_pin = ! align_pin; // Not supported, but wiggle the pin to escape
        new_pos = current_position;
        if (homed){
            if ( old_index != sense(1) ){
                if (motor_fwd){
                    new_pos += 1;
                    if (new_pos > inst_pockets) new_pos -= inst_pockets;
                }
                if (motor_rev) {
                    new_pos -= 1;
                    if (new_pos < 1) new_pos += inst_pockets;
                }
            }
            old_index = sense(1);
        }
        break;
    case 'C': // encoder or stepgen counts.
        new_pos = current_position;
        if (homed){
            int c;
            int t;
            int w = width / 2;
            c = (counts - base_counts);
            t = floor(((float)c + w) / scale);
            if (c >= (t * scale - w)  && c <= (t * scale + w)) {
                new_pos = 1 + (t % inst_pockets);
                // C modulus of negative numbers is inconvenient
                if (new_pos < 1) new_pos += inst_pockets;
            }
            align_pin = (c % scale <= 2 && c % scale >= -2); // don't try to align to an exact count.
        }
    }

    if (strobe) {
        current_position = new_pos;
        parity_error = (pcalc != (inst_parity ^ parity_));
    }
    mod_pocket = ((pocket_number - 1) % inst_pockets) + 1;
    // mod is odd with negatives, so just in case
    if (mod_pocket < 1) mod_pocket = 1;
    if (mod_pocket > inst_pockets) mod_pocket = inst_pockets;

    if (unhome && ! old_unhome) homed = 0;
    old_unhome = unhome;

    switch (state){
    case 0: // waiting at start
        motor_dir = 0;
        if (jog_fwd || (jog_rev && inst_dir == 2))  {
            if ((inst_code == 'I' || inst_code == 'E' || inst_code == 'C') && ! homed){
                state = 10;
                break;
            }
            target = current_position + jog_fwd - jog_rev;
            counts_target += scale * (target - current_position);
            if (target > inst_pockets ) target = 1;
            if (target < 1) target = inst_pockets;
            if (jog_fwd){
                motor_fwd = 1;
                motor_rev = 0;
                motor_vel = fwd_dc;
                motor_dir = 1;
            }
            if (jog_rev){
                motor_fwd = 0;
                motor_rev = 1;
                motor_vel = rev_dc;
                motor_dir = -1;
            }
            active = 1;
            state = 20;
            break;
        }
        motor_vel = hold_dc;
        if (! enable) return ;
        active = 1;
        if ((inst_code == 'I' || inst_code == 'E' || inst_code == 'C') && ! homed){
            state = 10;
            break;
        }
        state = 1;
        ready = 0;
    case 1: // choose direction
        if (mod_pocket < 1 || mod_pocket > inst_pockets) {
            state = 0;
            return;
        }
        if (inst_dir == 2){
            if (current_position < mod_pocket){
                if (mod_pocket - current_position > (inst_pockets / 2)) {
                    motor_fwd = 0;
                    motor_rev = 1;
                    motor_vel = rev_dc;
                    motor_dir = -1;
                    counts_target += (mod_pocket - current_position - inst_pockets) * scale;
                } else {
                    motor_fwd = 1;
                    motor_rev = 0;
                    motor_vel = fwd_dc;
                    motor_dir = 1;
                    counts_target += (mod_pocket - current_position ) * scale;
                }
            } else {
                if (current_position - mod_pocket > (inst_pockets / 2)) {
                    motor_fwd = 1;
                    motor_rev = 0;
                    motor_vel = fwd_dc;
                    motor_dir = 1;
                    counts_target += (mod_pocket - current_position + inst_pockets) * scale;
                } else {
                    motor_fwd = 0;
                    motor_rev = 1;
                    motor_vel = rev_dc;
                    motor_dir = -1;
                    counts_target += (mod_pocket - current_position) * scale;
                }
            }
        } else {
            counts_target += (mod_pocket - current_position) * scale;
            if (counts_target < counts ) {
                counts_target += scale * inst_pockets;
            }
            motor_fwd = 1;
            motor_rev = 0;
            motor_vel = fwd_dc;
            motor_dir = 1;
        }
        state = 2;
    case 2: // moving
        if ((current_position != mod_pocket) && enable){
            deb = debounce;
            return;
        } else if (deb-- > 0) {
            return;
        }
        if (rev_pulse > 0){
            motor_fwd = 0;
            motor_rev = 1;
            motor_vel = rev_dc;
            timer = rev_pulse;        
            state = 3;
        } else if (decel_time > 0) {
            // stop and prepare for alignment
            motor_vel = 0;
            timer = decel_time;
            state = 5;
        } else {
            motor_fwd = 0;
            motor_rev = 0;
            motor_vel = hold_dc;
            active = 0;
            if (enable && current_position == mod_pocket) ready = 1;
            state = 9;
        }
        break;
    case 3: // timed reverse pulse
        timer -= fperiod;
        if (timer > 0) return;
        state = 9;
        motor_fwd = 0;
        motor_rev = 0;
        motor_vel = hold_dc;
        active = 0;
        if (enable) ready = 1;
        break;
    case 5: //Waiting for carousel to stop
        timer -= fperiod;
        if (timer > 0) return;
        if (align_dc == 0){
            state = 8;
            break;
        }
        motor_vel = -align_dc;
        if (motor_dir == 1) {
            state = 6;
        } else {
            state = 7;
        }
        break;
    case 6: //backing up to index
        if ( align_pin == 0 ) return;
        state = 7;
        break;
    case 7: //backing back off of index
        if ( align_pin != 0 ) return;
        motor_vel = align_dc;
        state = 8;
        break;
    case 8: // final move back to index
        if ( align_pin == 0 ) return;
        motor_fwd = 0;
        motor_rev = 0;
        motor_vel = hold_dc;
        active = 0;
        // final safety check for in-position
        if (enable && current_position == mod_pocket) ready = 1;
        state = 9;
        break;
    case 9: //waiting for enable to go false
        if (! ready && ! err_once){
            rtapi_print_msg(RTAPI_MSG_ERR, "The toolchanger has failed the final alignment check");
            err_once = 1;
        }
        if (enable) return;
        err_once = 0;
        state = 0;
        break;
    case 10: // start of homing
        homed = 0;
        homing = 1;
        motor_fwd = 1;
        motor_rev = 0;
        motor_vel = fwd_dc;
        motor_dir = 1;
        index_enable = 1;
        counts_target += scale * inst_pockets;
        old_index = 1; // ensure 0->1 cycle of home sensor
        state = 11;
    case 11: ;// waiting for index & pulse
        int ind = 0;
        if (inst_code == 'C'){
            ind = sense(0);
        } else {
            ind = (sense(0) && sense(1));
        }
        if  ( ! index_enable || ((! old_index) && ind)){ // index found
            current_position = 1;
            homed = 1;
            homing = 0;
            active = 0;
            motor_fwd = 0;
            motor_rev = 0;
            motor_vel = 0;
            base_counts = counts - home_offset;
            counts_target = base_counts;
            if ( align_dc == 0) {
                state = 0;
            } else { 
                timer = decel_time;
                state = 5;
            }
        }
        old_index = ind;
        break; // So that we don't see the tool1 pulse twice
    case 20: //jogging fwd/rev
        if (current_position != target){
            deb = debounce;
            return;
        } else if (deb-- > 0) {
            return;
        }
        if (align_dc != 0 && ! align_pin) return;
        motor_fwd = 0;
        motor_rev = 0;
        motor_vel = hold_dc;
        active = 0;
        if (jog_fwd || jog_rev) return; // require button release to jog again
        if (align_dc != 0) {
            motor_vel = -align_dc;
            timer = decel_time;
            state = 5;
        } else {
            state = 0;
        }
        break;
    }
}

EXTRA_SETUP(){
    if (pockets[extra_arg] > 0) default_pockets = pockets[extra_arg];
    if (encoding[extra_arg] == NULL) {
        //it's already default_code
    } else if (strncmp(encoding[extra_arg], "gray", 4) == 0) {
        default_code = 'G';
    } else if (strncmp(encoding[extra_arg], "binary", 6) == 0) {
        default_code = 'B';
    } else if (strncmp(encoding[extra_arg], "bcd", 3) == 0) {
        default_code = 'D';
    } else if (strncmp(encoding[extra_arg], "single", 6) == 0) {
        default_code = 'S';
    } else if (strncmp(encoding[extra_arg], "index", 5) == 0) {
        default_code = 'I';
    } else if (strncmp(encoding[extra_arg], "edge", 4) == 0) {
        default_code = 'E';
    } else if (strncmp(encoding[extra_arg], "counts", 6) == 0) {
        default_code = 'C';
    }

    if (dir[extra_arg] > 0)  default_dir = (dir[extra_arg] > 1)? 2:1;

    if (parity[extra_arg] != -1) default_parity = parity[extra_arg];
    
    if (default_code == 'I') {
        default_sense = 2;
    } else if (num_sense[extra_arg] > 0 ) {
        default_sense = num_sense[extra_arg];
    }
    
    inst_pockets = default_pockets;
    inst_code = default_code;
    inst_dir = default_dir;
    inst_sense = default_sense;
    inst_parity = default_parity;

    if (inst_code == 'S' && inst_sense < inst_pockets) inst_sense = inst_pockets;
    personality = inst_sense;

    return 0;
}

int get_count(void){
    int i;
    for (i = 0; pockets[i] != 0 && i < MAX_CHAN; i++){}
    if (i == 0) return 1 ;
    return i;
}