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Cooling: add per-printer non-zero fan PWM floor and fix N=0 fan ramp override (#13715)

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* Cooling: add per-printer non-zero fan PWM floor and fix N=0 ramp override
* updated parameter naming
This commit is contained in:
Ioannis Giannakas
2026-05-19 09:40:53 +01:00
committed by GitHub
parent b08ed2f93b
commit 0a11a48a6e
9 changed files with 61 additions and 18 deletions
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29
src/libslic3r/GCode/CoolingBuffer.cpp
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@@ -719,6 +719,9 @@ std::string CoolingBuffer::apply_layer_cooldown(
// Second generate the adjusted G-code.
std::string new_gcode;
new_gcode.reserve(gcode.size() * 2);
// ORCA: per-printer minimum non-zero fan PWM. Applied at every part-cooling fan emission below so any
// non-zero command is raised to at least this percent (0 disables the clamp).
const unsigned int part_cooling_fan_min_pwm = static_cast<unsigned int>(std::max(0, m_config.part_cooling_fan_min_pwm.value));
bool overhang_fan_control= false;
int overhang_fan_speed = 0;
bool internal_bridge_fan_control= false; // ORCA: Add support for separate internal bridge fan speed control
@@ -727,7 +730,7 @@ std::string CoolingBuffer::apply_layer_cooldown(
int supp_interface_fan_speed = 0;
bool ironing_fan_control= false; // ORCA: Add support for ironing fan speed control
int ironing_fan_speed = 0; // ORCA: Add support for ironing fan speed control
auto change_extruder_set_fan = [ this, layer_id, layer_time, &new_gcode,
auto change_extruder_set_fan = [ this, layer_id, layer_time, &new_gcode, part_cooling_fan_min_pwm,
&overhang_fan_control, &overhang_fan_speed,
&internal_bridge_fan_control, &internal_bridge_fan_speed,
&supp_interface_fan_control, &supp_interface_fan_speed,
@@ -743,11 +746,11 @@ std::string CoolingBuffer::apply_layer_cooldown(
int full_fan_speed_layer = EXTRUDER_CONFIG(full_fan_speed_layer);
supp_interface_fan_speed = EXTRUDER_CONFIG(support_material_interface_fan_speed);
if (close_fan_the_first_x_layers <= 0 && full_fan_speed_layer > 0) {
// When ramping up fan speed from close_fan_the_first_x_layers to full_fan_speed_layer, force close_fan_the_first_x_layers above zero,
// so there will be a zero fan speed at least at the 1st layer.
close_fan_the_first_x_layers = 1;
}
// ORCA: previously a silent override forced `close_fan_the_first_x_layers` from 0 up to 1 whenever a ramp
// was configured (`full_fan_speed_layer > 0`), so the first printed layer always had the fan disabled.
// That hid the user's literal "no cooling for the first 0 layers" setting and produced a non-zero starting
// factor on the ramp denominator. The override has been removed: with N=0 and M>0 the ramp now genuinely
// starts on layer 0 at a factor of 1/M and reaches 100% at layer M-1, matching the intent of the option.
if (int(layer_id) >= close_fan_the_first_x_layers) {
float fan_max_speed = EXTRUDER_CONFIG(fan_max_speed);
float slow_down_layer_time = float(EXTRUDER_CONFIG(slow_down_layer_time));
@@ -806,7 +809,7 @@ std::string CoolingBuffer::apply_layer_cooldown(
m_fan_speed = fan_speed_new;
m_current_fan_speed = fan_speed_new;
if (immediately_apply)
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_fan_speed, part_cooling_fan_min_pwm);
}
//BBS
if (additional_fan_speed_new != m_additional_fan_speed) {
@@ -980,26 +983,26 @@ std::string CoolingBuffer::apply_layer_cooldown(
if (need_set_fan) {
if (fan_speed_change_requests[CoolingLine::TYPE_OVERHANG_FAN_START]){
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, overhang_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, overhang_fan_speed, part_cooling_fan_min_pwm);
m_current_fan_speed = overhang_fan_speed;
} else if (fan_speed_change_requests[CoolingLine::TYPE_INTERNAL_BRIDGE_FAN_START]){ // ORCA: Add support for separate internal bridge fan speed control
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, internal_bridge_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, internal_bridge_fan_speed, part_cooling_fan_min_pwm);
m_current_fan_speed = internal_bridge_fan_speed;
}
else if (fan_speed_change_requests[CoolingLine::TYPE_SUPPORT_INTERFACE_FAN_START]){
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, supp_interface_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, supp_interface_fan_speed, part_cooling_fan_min_pwm);
m_current_fan_speed = supp_interface_fan_speed;
}
else if (fan_speed_change_requests[CoolingLine::TYPE_IRONING_FAN_START]){
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, ironing_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, ironing_fan_speed, part_cooling_fan_min_pwm);
m_current_fan_speed = ironing_fan_speed;
}
else if(fan_speed_change_requests[CoolingLine::TYPE_FORCE_RESUME_FAN] && m_current_fan_speed != -1){
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_current_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_current_fan_speed, part_cooling_fan_min_pwm);
fan_speed_change_requests[CoolingLine::TYPE_FORCE_RESUME_FAN] = false;
}
else
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_fan_speed);
new_gcode += GCodeWriter::set_fan(m_config.gcode_flavor, m_fan_speed, part_cooling_fan_min_pwm);
need_set_fan = false;
}
pos = line_end;

5
src/libslic3r/GCode/FanMover.cpp
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@@ -230,7 +230,10 @@ void FanMover::_remove_slow_fan(int16_t min_speed, float past_sec) {
std::string FanMover::_set_fan(int16_t speed) {
//const Tool* tool = m_writer.get_tool(m_currrent_extruder < 20 ? m_currrent_extruder : 0);
return GCodeWriter::set_fan(m_writer.config.gcode_flavor.value, speed);
// ORCA: apply the per-printer non-zero fan PWM floor so reposted fan commands respect the clamp too.
const int floor_pct = m_writer.config.part_cooling_fan_min_pwm.value;
const unsigned int part_cooling_fan_min_pwm = floor_pct > 0 ? static_cast<unsigned int>(floor_pct) : 0u;
return GCodeWriter::set_fan(m_writer.config.gcode_flavor.value, speed, part_cooling_fan_min_pwm);
}

10
src/libslic3r/GCodeWriter.cpp
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@@ -1092,9 +1092,13 @@ std::string GCodeWriter::unlift()
return gcode;
}
std::string GCodeWriter::set_fan(const GCodeFlavor gcode_flavor, unsigned int speed)
std::string GCodeWriter::set_fan(const GCodeFlavor gcode_flavor, unsigned int speed, unsigned int part_cooling_fan_min_pwm)
{
std::ostringstream gcode;
// ORCA: clamp non-zero fan commands up to the configured PWM floor so fans that can't spool at low duty
// cycles still start reliably. Zero (fan off) is preserved exactly so disable-fan commands are never altered.
if (speed > 0 && part_cooling_fan_min_pwm > 0 && speed < part_cooling_fan_min_pwm)
speed = part_cooling_fan_min_pwm;
if (speed == 0) {
switch (gcode_flavor) {
case gcfTeacup:
@@ -1129,7 +1133,9 @@ std::string GCodeWriter::set_fan(const GCodeFlavor gcode_flavor, unsigned int sp
std::string GCodeWriter::set_fan(unsigned int speed) const
{
//BBS
return GCodeWriter::set_fan(this->config.gcode_flavor, speed);
// ORCA: pick up the per-printer PWM floor from the active config.
return GCodeWriter::set_fan(this->config.gcode_flavor, speed,
static_cast<unsigned int>(std::max(0, this->config.part_cooling_fan_min_pwm.value)));
}
//BBS: set additional fan speed for BBS machine only

4
src/libslic3r/GCodeWriter.hpp
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@@ -98,7 +98,9 @@ public:
void set_xy_offset(double x, double y) { m_x_offset = x; m_y_offset = y; }
Vec2f get_xy_offset() { return Vec2f{m_x_offset, m_y_offset}; };
// To be called by the CoolingBuffer from another thread.
static std::string set_fan(const GCodeFlavor gcode_flavor, unsigned int speed);
// ORCA: `part_cooling_fan_min_pwm` (0-100, default 0) is a floor applied only when `speed` is non-zero, used to overcome
// PWM start-up thresholds on fans that won't spool below a certain duty cycle. A `speed` of 0 is always honoured.
static std::string set_fan(const GCodeFlavor gcode_flavor, unsigned int speed, unsigned int part_cooling_fan_min_pwm = 0);
// To be called by the main thread. It always emits the G-code, it does not remember the previous state.
// Keeping the state is left to the CoolingBuffer, which runs asynchronously on another thread.
std::string set_fan(unsigned int speed) const;

2
src/libslic3r/Preset.cpp
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@@ -1326,7 +1326,7 @@ static std::vector<std::string> s_Preset_machine_limits_options {
static std::vector<std::string> s_Preset_printer_options {
"printer_technology",
"printable_area", "extruder_printable_area", "bed_exclude_area","bed_custom_texture", "bed_custom_model", "gcode_flavor",
"fan_kickstart", "fan_speedup_time", "fan_speedup_overhangs",
"fan_kickstart", "part_cooling_fan_min_pwm", "fan_speedup_time", "fan_speedup_overhangs",
"single_extruder_multi_material", "manual_filament_change", "file_start_gcode", "machine_start_gcode", "machine_end_gcode", "before_layer_change_gcode", "printing_by_object_gcode", "layer_change_gcode", "time_lapse_gcode", "wrapping_detection_gcode", "change_filament_gcode", "change_extrusion_role_gcode",
"printer_model", "printer_variant", "printer_extruder_id", "printer_extruder_variant", "extruder_variant_list", "default_nozzle_volume_type",
"printable_height", "extruder_printable_height", "extruder_clearance_radius", "extruder_clearance_height_to_lid", "extruder_clearance_height_to_rod",

1
src/libslic3r/Print.cpp
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@@ -133,6 +133,7 @@ bool Print::invalidate_state_by_config_options(const ConfigOptionResolver & /* n
"fan_cooling_layer_time",
"full_fan_speed_layer",
"fan_kickstart",
"part_cooling_fan_min_pwm",
"fan_speedup_overhangs",
"fan_speedup_time",
"filament_colour",

22
src/libslic3r/PrintConfig.cpp
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@@ -3724,6 +3724,28 @@ void PrintConfigDef::init_fff_params()
def->mode = comAdvanced;
def->set_default_value(new ConfigOptionFloat(0));
// ORCA: minimum non-zero part cooling fan speed.
def = this->add("part_cooling_fan_min_pwm", coInt);
def->label = L("Minimum non-zero part cooling fan speed");
def->tooltip = L("Some part-cooling fans cannot start spinning when commanded below a certain PWM duty cycle. "
"When set above 0, any non-zero part-cooling fan command will be raised to at least this percentage "
"so the fan reliably starts. A fan command of 0 (fan off) is always honoured exactly. "
"This clamp is applied after every other fan calculation (first-layer ramp, layer-time interpolation, "
"overhang/bridge/support-interface/ironing overrides), so scaling still operates within the range "
"[this value, 100%]."
"\nIf your firmware already disables the fan below a threshold (for example Klipper's "
"[fan] off_below: 0.10 shuts the fan off whenever the commanded duty cycle is below 10%), "
"this option and the firmware threshold should ideally be set to the same value. Matching them "
"(e.g. off_below: 0.10 in Klipper and 10% here) guarantees the slicer never emits a non-zero "
"value that the firmware would silently drop, and the fan never receives a value below the one "
"you know it can actually spool at."
"\nSet to 0 to deactivate.");
def->sidetext = L("%");
def->min = 0;
def->max = 100;
def->mode = comAdvanced;
def->set_default_value(new ConfigOptionInt(0));
def = this->add("time_cost", coFloat);
def->label = L("Time cost");

4
src/libslic3r/PrintConfig.hpp
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@@ -1309,6 +1309,10 @@ PRINT_CONFIG_CLASS_DEFINE(
((ConfigOptionFloat, fan_kickstart))
((ConfigOptionBool, fan_speedup_overhangs))
((ConfigOptionFloat, fan_speedup_time))
// ORCA: minimum PWM (as a percent 0-100) emitted when the part-cooling fan is asked for a non-zero speed.
// Used to overcome the PWM start-up threshold on fans that cannot spool below a certain duty cycle.
// A value of 0 (the default) leaves behaviour unchanged. A fan command of 0 (off) is always honoured.
((ConfigOptionInt, part_cooling_fan_min_pwm))
((ConfigOptionFloats, filament_diameter))
((ConfigOptionBoolsNullable, filament_adaptive_volumetric_speed))
((ConfigOptionStrings, volumetric_speed_coefficients))

2
src/slic3r/GUI/Tab.cpp
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@@ -4500,6 +4500,8 @@ void TabPrinter::build_fff()
line.append_option(optgroup->get_option("fan_speedup_overhangs"));
optgroup->append_line(line);
optgroup->append_single_option_line("fan_kickstart", "printer_basic_information_cooling_fan#fan-kick-start-time");
// ORCA: PWM floor for fans that won't spool at low duty cycles.
optgroup->append_single_option_line("part_cooling_fan_min_pwm", "printer_basic_information_cooling_fan#minimum-non-zero-part-cooling-fan-speed");
optgroup = page->new_optgroup(L("Extruder Clearance"), "param_extruder_clearance");
optgroup->append_single_option_line("extruder_clearance_radius", "printer_basic_information_extruder_clearance#radius");