New heater tuning algorithm
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@jbarros said in New heater tuning algorithm:
I'm available for testing too when the firmware for the Toolboards is available
see
https://forum.duet3d.com/topic/19763/reprapfirmware-3-2beta3-2-released -
@Veti my understanding of dc42's post is that the new heater tuning algorithm is going to be tested on the 6HC and if all goes well Toolboard and Expansions will be supported on the final release.
I was hoping to test it before the final release so it gets more exposure but alas not my decision.Nonetheless I tried running the auto tune just to check if you might be right but not yet:
M303 T0 Error: M303: remote heater auto tune not implemented
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have you updated the toolboard as per the changelog?
[Duet 3 + expansion/tool boards] You must also update expansion and tool board firmwares to 3.2beta3.2, otherwise heaters on expansion/tool boards will not work properly
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I am waiting for feedback from users of all Duet Wifi/Ethernet, Maestro and Duet 3 main boards on this new algorithm in RRF3.2beta3.2. If and when I have enough feedback to confirm that the new algorithm is working well, I will implement it on tool and expansion boards.
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@dc42 is it typical now that the tuning now Carey's put the cycle 5 times?
I also wasn't clear whether I should be starting the tune with the fan on? Also, what difference does it make using the T value? Is the preferred method to use the tool number?
Will this affect tuning of beds much or is it mainly aimed at hotends? -
Hi David,
a quick bit of feedback on the new heater tuning mechanism when it is used with the LPC port.On the LPC the ADC is quite noisy to the extent that we have a pre-filter on the readings (that uses a median filter). On my test machine I tested with just that filter and with the standard RRF temperature filter disabled. In this configuration I occasionally (about 50% of the time) had a result in which the tuning was not consistent and so ran for the max 30 cycles (with the fan not being used) and produced a warning message.
If I enable the RRF filter (in addition to the pre-filter) then the same printer completes the test in from 5 to 7 cycles (again with the "fan on" test not run). This same hardware ran the old algorithm fine with the RRF filter disabled. I suspect that this may mean that the new algorithm may be slightly more sensitive to noise than the older one. I'm not sure if this is an issue (especially with Duet hardware), but I thought it might be of interest.
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When doing this with the bed heater, phase 3 also says "fan off". This is likely just a cosmetic issue, as the part cooling fan wasn't on during the first couple cycles.
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@oliof said in New heater tuning algorithm:
When doing this with the bed heater, phase 3 also says "fan off". This is likely just a cosmetic issue, as the part cooling fan wasn't on during the first couple cycles.
Are you saying that the bed heater tuning also runs multiple cycles? If so, is that the number of cycles changeable by the user ? If not, that would be huge problem with a big, thick, insulated build plate such as I have because it takes maybe 50 minutes to cool. So one heater tuning cycle using the current algorithm takes about an hour or more and I most certainly wouldn't want to have to repeat that multiple times.
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@deckingman said in New heater tuning algorithm:
Are you saying that the bed heater tuning also runs multiple cycles? If so, is that the number of cycles changeable by the user ? If not, that would be huge problem with a big, thick, insulated build plate such as I have because it takes maybe 50 minutes to cool. So one heater tuning cycle using the current algorithm takes about an hour or more and I most certainly wouldn't want to have to repeat that multiple times.
It doesn't cycle fully, just by 5 degrees
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What Jay said, and then: If you do need to do multiple runs for different target temperatures, the new "A" parameter for ambient temperature allows you to start a new cycle before the bed cooled down. So you will likely save some time compared to previously if you need PID tuning for different target temps, because you could go and run it for 60, then 80, then 100C, and would not need to wait until the bed cools down to 30 inbetween. So depending on the way you do manage your PIDs, the process is only marginally longer, or may even be shorter with a larger bed.
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@deckingman said in New heater tuning algorithm:
@oliof said in New heater tuning algorithm:
When doing this with the bed heater, phase 3 also says "fan off". This is likely just a cosmetic issue, as the part cooling fan wasn't on during the first couple cycles.
Are you saying that the bed heater tuning also runs multiple cycles? If so, is that the number of cycles changeable by the user ? If not, that would be huge problem with a big, thick, insulated build plate such as I have because it takes maybe 50 minutes to cool. So one heater tuning cycle using the current algorithm takes about an hour or more and I most certainly wouldn't want to have to repeat that multiple times.
Since I also have build as a job a printer with a huge aluminum-plate (I think it was 750x750x8 or 10mm or so) I would also support that multiple cycles can be "optional" limited (which is the same as disabled if you put the limit to 1 cycle), because each cycle just takes too long... If the optional variable is not put, the system would do by default the amount of cycles it needs (the new approach)...
By this those kind of printers with huge thermal-mass-print-plates could benefit by the multiple-cycle approach for the extruder but could avoid its side-effects regarding the heat-plate ? Because of the huge thermal mass of those print-plates if the corridor of the PID algorithm for the temp-sensor-limits are narrow enough and resolution of the temp-sensor is high and it is a fast-reacting sensor, maybe 1 cycle could be enough for the plate? It would be also a fall-back solution for those having trouble with the new approach for whatever reason... This implicates that "the first cycle" (and ONLY this one) would behave like as we are used to it (old style)? -
@gloomyandy said in New heater tuning algorithm:
Hi David,
a quick bit of feedback on the new heater tuning mechanism when it is used with the LPC port.On the LPC the ADC is quite noisy to the extent that we have a pre-filter on the readings (that uses a median filter). On my test machine I tested with just that filter and with the standard RRF temperature filter disabled. In this configuration I occasionally (about 50% of the time) had a result in which the tuning was not consistent and so ran for the max 30 cycles (with the fan not being used) and produced a warning message.
If I enable the RRF filter (in addition to the pre-filter) then the same printer completes the test in from 5 to 7 cycles (again with the "fan on" test not run). This same hardware ran the old algorithm fine with the RRF filter disabled. I suspect that this may mean that the new algorithm may be slightly more sensitive to noise than the older one. I'm not sure if this is an issue (especially with Duet hardware), but I thought it might be of interest.
The old algorithm calculated the heating rate using the entire time to heat up. from room temperature to target temperature. Likewise it calculated the cooling time by monitoring a long cooldown time at the end. The new algorithm cycles between the target temperature and 5C below it. It measures the heating and cooling rates on the last 3C each cycle, and accumulates the mean and standard deviation. If there is a lot of noise in the ADC readings then that noise will be a greater proportion of that 3C, so the data quality (as shown by the standard deviation) will be less good and it will do more cycles.
You could try increasing that 5C value to reduce the effect of noise, although it will lengthen the tuning process. It's TuningHysteresis in LocalHeater.h.
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@LB, I suggest you try the new algorithm on your bed heater. The new algorithm doesn't need the long cooldown period at the end, so it won't necessarily take longer.
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@oliof said in New heater tuning algorithm:
What Jay said, and then: If you do need to do multiple runs for different target temperatures, the new "A" parameter for ambient temperature allows you to start a new cycle before the bed cooled down.
That's true; but it should not normally be necessary to tune at more than one temperature. An exception might be if you use a heated chamber and the chamber temperature varies a lot depending on the material.
BTW in you use a heated chamber then the tuning for the hot end heaters should be done with the chamber up to temperature, and "ambient temperature" will be the chamber temperature.
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Another use may be multizone heaters like Keenoovo offers for larger beds I guess.
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Thanks as usual! Just a bit worried.
At the moment can only test with the smaller "renewed" (via the duet-board) anycubic here. With this little 220x220mm plate, I guess it will be fine.
The other printer with the big plate is a few hundred km away...(If all duet-boards supporting RRF3.x have enough storage-space another option would be to make it optional via M307 the B-parameter there, 0 for PID, 1 for bang-bang, 2 for the "new iterating PID" or similar...? Just thinking out loud)
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@dc42 said in New heater tuning algorithm:
@LB, I suggest you try the new algorithm on your bed heater. The new algorithm doesn't need the long cooldown period at the end, so it won't necessarily take longer.
But does it still need to "cycle" the temperature by 5 deg C or so? That in itself is likely to be problematic with a large (and insulated) thermal mass.
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Very nice to see betaflight features implemented here
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@deckingman said in New heater tuning algorithm:
@dc42 said in New heater tuning algorithm:
@LB, I suggest you try the new algorithm on your bed heater. The new algorithm doesn't need the long cooldown period at the end, so it won't necessarily take longer.
But does it still need to "cycle" the temperature by 5 deg C or so? That in itself is likely to be problematic with a large (and insulated) thermal mass.
If the overshoot and undershoot is small and the temperature sensors are not noisy, then it would be possible to use a smaller temperature range.
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I originally posted by mistake in 3.2-beta3.2 thread, but I think it is better here...
I've been testing the new algorithm on my printer and have seen some strange results when tuning the bed heater. My bed is a 310x310x6mm aluminium plate with a magnetically attached steel sheet on top. The heater is a mains powered 250x250mm 500W Silicon pad (with the thermistor embedded in it). When tuning my target temperature is 60 degrees. Ambient temperature is around 21 degrees. This combination is probably not ideal as there is a lot of lag between the pad thermistor and the actual bed plate temperature.
If I run the tuning from cold then it always seems to run for the full 30 cycles. However if I run it when it has cooled (from 60) to say 30 degrees (using the A parameter to specify the ambient temperature) then it will complete after 5 cycles. To try and understand what is going on I have added some additional debug to the tuning process. Here is the output from the first case:
Auto tune starting phase 1, heater on Auto tune starting phase 2, heater settling Sample 1 dLow 1250.000000 tOn 11250.000000 heatingRate 0.585193 Sample 1 dHigh 1750.000000 tOff 22750.000000 coolingRate 0.268330 tOn 11250±0, tOff 22750±0, dHigh 1750±0, dLow 1250±0, R 0.585±0.000, C 0.268±0.000, V 0.0±0.0, cycles 1 Sample 2 dLow 1250.000000 tOn 11500.000000 heatingRate 0.581589 Sample 2 dHigh 2500.000000 tOff 25750.000000 coolingRate 0.234478 tOn 11375±125, tOff 24250±1500, dHigh 2125±375, dLow 1250±0, R 0.583±0.002, C 0.251±0.017, V 0.0±0.0, cycles 2 Auto tune starting phase 3, fan off Sample 1 dLow 1000.000000 tOn 10750.000000 heatingRate 0.608868 Sample 1 dHigh 2500.000000 tOff 28250.000000 coolingRate 0.222683 tOn 10750±0, tOff 28250±5, dHigh 2500±0, dLow 1000±0, R 0.609±0.000, C 0.223±0.000, V 0.0±0.0, cycles 1 Sample 2 dLow 1250.000000 tOn 10250.000000 heatingRate 0.629652 Sample 2 dHigh 2750.000000 tOff 30750.000000 coolingRate 0.197948 tOn 10500±250, tOff 29500±1250, dHigh 2625±125, dLow 1125±125, R 0.619±0.010, C 0.210±0.012, V 0.0±0.0, cycles 2 Sample 3 dLow 1000.000000 tOn 9750.000000 heatingRate 0.676344 Sample 3 dHigh 2250.000000 tOff 34000.000000 coolingRate 0.179575 tOn 10250±408, tOff 31000±2354, dHigh 2500±204, dLow 1083±118, R 0.638±0.028, C 0.200±0.018, V 0.0±0.0, cycles 3 Sample 4 dLow 1250.000000 tOn 9750.000000 heatingRate 0.678182 Sample 4 dHigh 2250.000000 tOff 37500.000000 coolingRate 0.164589 tOn 10125±415, tOff 32625±3475, dHigh 2438±207, dLow 1125±125, R 0.648±0.030, C 0.191±0.022, V 0.0±0.0, cycles 4 Sample 5 dLow 750.000000 tOn 9250.000000 heatingRate 0.724365 Sample 5 dHigh 2500.000000 tOff 40000.000000 coolingRate 0.153312 tOn 9950±510, tOff 34100±4285, dHigh 2450±187, dLow 1050±187, R 0.663±0.041, C 0.184±0.025, V 0.0±0.0, cycles 5 Sample 6 dLow 1000.000000 tOn 9250.000000 heatingRate 0.710471 Sample 6 dHigh 3000.000000 tOff 43500.000000 coolingRate 0.142683 tOn 9833±534, tOff 35667±5251, dHigh 2542±267, dLow 1042±172, R 0.671±0.041, C 0.177±0.027, V 0.0±0.0, cycles 6 Sample 7 dLow 1000.000000 tOn 9000.000000 heatingRate 0.728104 Sample 7 dHigh 3000.000000 tOff 46500.000000 coolingRate 0.134402 tOn 9714±574, tOff 37214±6165, dHigh 2607±295, dLow 1036±160, R 0.679±0.043, C 0.171±0.029, V 0.0±0.0, cycles 7 Sample 8 dLow 750.000000 tOn 8750.000000 heatingRate 0.762012 Sample 8 dHigh 2500.000000 tOff 49500.000000 coolingRate 0.128104 tOn 9594±624, tOff 38750±7054, dHigh 2594±278, dLow 1000±177, R 0.690±0.048, C 0.165±0.031, V 0.0±0.0, cycles 8 Sample 9 dLow 1000.000000 tOn 9000.000000 heatingRate 0.740379 Sample 9 dHigh 3000.000000 tOff 52250.000000 coolingRate 0.125191 tOn 9528±617, tOff 40250±7889, dHigh 2639±291, dLow 1000±167, R 0.695±0.048, C 0.161±0.032, V 0.0±0.0, cycles 9 Sample 10 dLow 1000.000000 tOn 9000.000000 heatingRate 0.765968 Sample 10 dHigh 3500.000000 tOff 57000.000000 coolingRate 0.110748 tOn 9475±607, tOff 41925±9015, dHigh 2725±378, dLow 1000±158, R 0.702±0.051, C 0.156±0.034, V 0.0±0.0, cycles 10 Sample 11 dLow 750.000000 tOn 9000.000000 heatingRate 0.739456 Sample 11 dHigh 2500.000000 tOff 58000.000000 coolingRate 0.106328 tOn 9432±594, tOff 43386±9759, dHigh 2705±366, dLow 977±167, R 0.706±0.049, C 0.151±0.035, V 0.0±0.0, cycles 11 Sample 12 dLow 500.000000 tOn 8750.000000 heatingRate 0.766151 Sample 12 dHigh 3000.000000 tOff 60750.000000 coolingRate 0.104071 tOn 9375±599, tOff 44833±10504, dHigh 2729±360, dLow 938±207, R 0.711±0.050, C 0.147±0.036, V 0.0±0.0, cycles 12 Sample 13 dLow 750.000000 tOn 8750.000000 heatingRate 0.743942 Sample 13 dHigh 3250.000000 tOff 61500.000000 coolingRate 0.103689 tOn 9327±600, tOff 46115±11026, dHigh 2769±373, dLow 923±205, R 0.713±0.049, C 0.144±0.037, V 0.0±0.0, cycles 13 Sample 14 dLow 750.000000 tOn 8750.000000 heatingRate 0.793538 Sample 14 dHigh 3500.000000 tOff 62500.000000 coolingRate 0.101916 tOn 9286±597, tOff 47286±11432, dHigh 2821±406, dLow 911±203, R 0.719±0.051, C 0.141±0.037, V 0.0±0.0, cycles 14 Sample 15 dLow 0.000000 tOn 8750.000000 heatingRate 0.053600 Sample 15 dHigh 3500.000000 tOff 63250.000000 coolingRate 0.098418 tOn 9250±592, tOff 48350±11740, dHigh 2867±427, dLow 850±300, R 0.675±0.173, C 0.138±0.037, V 0.0±0.0, cycles 15 Sample 16 dLow 500.000000 tOn 8500.000000 heatingRate 0.790129 Sample 16 dHigh 3250.000000 tOff 64000.000000 coolingRate 0.097789 tOn 9203±601, tOff 49328±11982, dHigh 2891±424, dLow 828±303, R 0.682±0.170, C 0.136±0.037, V 0.0±0.0, cycles 16 Sample 17 dLow 0.000000 tOn 8750.000000 heatingRate 0.056186 Sample 17 dHigh 3250.000000 tOff 64250.000000 coolingRate 0.100125 tOn 9176±593, tOff 50206±12143, dHigh 2912±420, dLow 779±352, R 0.645±0.221, C 0.134±0.037, V 0.0±0.0, cycles 17 Sample 18 dLow 750.000000 tOn 8250.000000 heatingRate 0.805200 Sample 18 dHigh 3000.000000 tOff 64250.000000 coolingRate 0.096790 tOn 9125±614, tOff 50986±12231, dHigh 2917±408, dLow 778±342, R 0.654±0.218, C 0.132±0.037, V 0.0±0.0, cycles 18 Sample 19 dLow 750.000000 tOn 8500.000000 heatingRate 0.771688 Sample 19 dHigh 3000.000000 tOff 66000.000000 coolingRate 0.094537 tOn 9092±614, tOff 51776±12368, dHigh 2921±398, dLow 776±333, R 0.660±0.214, C 0.130±0.037, V 0.0±0.0, cycles 19 Sample 20 dLow 750.000000 tOn 8500.000000 heatingRate 0.797152 Sample 20 dHigh 3750.000000 tOff 65500.000000 coolingRate 0.094485 tOn 9062±612, tOff 52462±12421, dHigh 2962±428, dLow 775±325, R 0.667±0.211, C 0.128±0.037, V 0.0±0.0, cycles 20 Sample 21 dLow 1000.000000 tOn 8500.000000 heatingRate 0.781730 Sample 21 dHigh 3000.000000 tOff 66250.000000 coolingRate 0.097950 tOn 9036±609, tOff 53119±12472, dHigh 2964±418, dLow 786±321, R 0.673±0.207, C 0.126±0.037, V 0.0±0.0, cycles 21 Sample 22 dLow 0.000000 tOn 8500.000000 heatingRate 0.056254 Sample 22 dHigh 3500.000000 tOff 67500.000000 coolingRate 0.093961 tOn 9011±605, tOff 53773±12548, dHigh 2989±423, dLow 750±354, R 0.645±0.239, C 0.125±0.036, V 0.0±0.0, cycles 22 Sample 23 dLow 750.000000 tOn 8500.000000 heatingRate 0.789738 Sample 23 dHigh 3250.000000 tOff 66500.000000 coolingRate 0.094778 tOn 8989±601, tOff 54326±12544, dHigh 3000±417, dLow 750±346, R 0.651±0.236, C 0.124±0.036, V 0.0±0.0, cycles 23 Sample 24 dLow 750.000000 tOn 8500.000000 heatingRate 0.794132 Sample 24 dHigh 3750.000000 tOff 66250.000000 coolingRate 0.097583 tOn 8969±596, tOff 54823±12508, dHigh 3031±435, dLow 750±339, R 0.657±0.233, C 0.123±0.036, V 0.0±0.0, cycles 24 Sample 25 dLow 0.000000 tOn 8500.000000 heatingRate 0.055224 Sample 25 dHigh 3500.000000 tOff 66750.000000 coolingRate 0.095105 tOn 8950±592, tOff 55300±12477, dHigh 3050±436, dLow 720±363, R 0.633±0.257, C 0.121±0.035, V 0.0±0.0, cycles 25 Sample 26 dLow 1000.000000 tOn 8500.000000 heatingRate 0.797152 Sample 26 dHigh 3000.000000 tOff 66500.000000 coolingRate 0.095806 tOn 8933±587, tOff 55731±12422, dHigh 3048±428, dLow 731±360, R 0.639±0.254, C 0.120±0.035, V 0.0±0.0, cycles 26 Sample 27 dLow 1250.000000 tOn 8500.000000 heatingRate 0.793937 Sample 27 dHigh 3750.000000 tOff 66500.000000 coolingRate 0.093961 tOn 8917±581, tOff 56130±12359, dHigh 3074±440, dLow 750±366, R 0.645±0.251, C 0.120±0.035, V 0.0±0.0, cycles 27 Sample 28 dLow 1000.000000 tOn 8250.000000 heatingRate 0.805200 Sample 28 dHigh 3000.000000 tOff 65750.000000 coolingRate 0.093893 tOn 8893±584, tOff 56473±12267, dHigh 3071±432, dLow 759±363, R 0.651±0.248, C 0.119±0.034, V 0.0±0.0, cycles 28 Sample 29 dLow 750.000000 tOn 8500.000000 heatingRate 0.783488 Sample 29 dHigh 2750.000000 tOff 67000.000000 coolingRate 0.095667 tOn 8879±578, tOff 56836±12205, dHigh 3060±429, dLow 759±356, R 0.655±0.245, C 0.118±0.034, V 0.0±0.0, cycles 29 Sample 30 dLow 1000.000000 tOn 8500.000000 heatingRate 0.808610 Sample 30 dHigh 2750.000000 tOff 66750.000000 coolingRate 0.092288 tOn 8867±573, tOff 57167±12131, dHigh 3050±425, dLow 767±353, R 0.660±0.242, C 0.117±0.034, V 0.0±0.0, cycles 30 Warning: heater behaviour was not consistent during tuning tOn 8867±573, tOff 57167±12131, dHigh 3050±425, dLow 767±353, R 0.660±0.242, C 0.117±0.034, V 0.0±0.0, cycles 30 Auto tuning heater 0 completed after 30 cycles in 2137 seconds. This heater needs the following M307 command: M307 H0 R0.788 C289.8 D2.74 S1.00 V0.0 Edit the M307 H0 command in config.g to match this. Heater 0 switched off
and this is the output from the "pre-heated" case:
Auto tuning heater 0 using target temperature 60.0°C and PWM 1.00 - do not leave printer unattended ok Auto tune starting phase 2, heater settling Sample 1 dLow 750.000000 tOn 9250.000000 heatingRate 0.753922 Sample 1 dHigh 2250.000000 tOff 36000.000000 coolingRate 0.165439 tOn 9250±0, tOff 36000±0, dHigh 2250±0, dLow 750±0, R 0.754±0.000, C 0.165±0.000, V 0.0±0.0, cycles 1 Sample 2 dLow 1000.000000 tOn 9250.000000 heatingRate 0.727826 Sample 2 dHigh 2250.000000 tOff 40250.000000 coolingRate 0.155488 tOn 9250±0, tOff 38125±2125, dHigh 2250±0, dLow 875±125, R 0.741±0.013, C 0.160±0.005, V 0.0±0.0, cycles 2 Auto tune starting phase 3, fan off Sample 1 dLow 1000.000000 tOn 9500.000000 heatingRate 0.699097 Sample 1 dHigh 2500.000000 tOff 43500.000000 coolingRate 0.141769 tOn 9500±0, tOff 43500±0, dHigh 2500±0, dLow 1000±0, R 0.699±0.000, C 0.142±0.000, V 0.0±0.0, cycles 1 Sample 2 dLow 1250.000000 tOn 8750.000000 heatingRate 0.769238 Sample 2 dHigh 2500.000000 tOff 46250.000000 coolingRate 0.132351 tOn 9125±375, tOff 44875±1375, dHigh 2500±0, dLow 1125±125, R 0.734±0.035, C 0.137±0.005, V 0.0±0.0, cycles 2 Sample 3 dLow 750.000000 tOn 8750.000000 heatingRate 0.763718 Sample 3 dHigh 2750.000000 tOff 50750.000000 coolingRate 0.126651 tOn 9000±354, tOff 46833±2988, dHigh 2583±118, dLow 1000±204, R 0.744±0.032, C 0.134±0.006, V 0.0±0.0, cycles 3 Sample 4 dLow 1250.000000 tOn 8500.000000 heatingRate 0.800977 Sample 4 dHigh 3500.000000 tOff 53500.000000 coolingRate 0.115505 tOn 8875±375, tOff 48500±3877, dHigh 2812±410, dLow 1062±207, R 0.758±0.037, C 0.129±0.010, V 0.0±0.0, cycles 4 Sample 5 dLow 1250.000000 tOn 8500.000000 heatingRate 0.761442 Sample 5 dHigh 3500.000000 tOff 56250.000000 coolingRate 0.110297 tOn 8800±367, tOff 50050±4651, dHigh 2950±458, dLow 1100±200, R 0.759±0.033, C 0.125±0.011, V 0.0±0.0, cycles 5 tOn 8800±367, tOff 50050±4651, dHigh 2950±458, dLow 1100±200, R 0.759±0.033, C 0.125±0.011, V 0.0±0.0, cycles 5 Auto tuning heater 0 completed after 5 cycles in 460 seconds. This heater needs the following M307 command: M307 H0 R0.895 C267.3 D2.67 S1.00 V0.0 Edit the M307 H0 command in config.g to match this. Heater 0 switched off
I suspect that the relatively large thermal mass means that as the full bed heats up it is impacting the heating/cooling times of the test cycle. But there also seems to be something a little odd going on with the "dLow" values as these are sometimes zero.
It may well be that I need to add an additional thermistor (perhaps embedded in the edge of the bed) to get more accurate readings of the actual bed temperature. However I don't think the setup I have is that unusual so I thought the data might be of interest to you.