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Oleksandr ShyshatskyiandClaude Opus 5 7b4ce414b5 max_residual guards against a mis-trigger, not against probe scatter

The 0.05 mm default was derived from what the guard can resolve rather
than from what the machine actually measures: with four symmetric points
one bad point of error e shows up as only ~e/4 in the residual while
moving the fitted centre by e/2, so 0.05 trips at centre errors of about
0.1 mm. That is inside the ESTOP's own repeatability. A healthy run on a
Creator 5 Pro fits with a worst residual of 0.23, which the guard
rejected -- and rejecting means aborting without saving, so a good
calibration was thrown away.

Default is now 0.5, which trips at centre errors of about 1 mm. A probe
that missed the bore edge or fired on the way in still lands far outside
that; ordinary scatter of a couple of tenths passes. 0 still disables,
and the option is still settable per printer.

The other guards are unchanged: min_radius/max_radius are off by
default, gap_min/gap_max is a 1.5..5 mm window around a nominal 3.2 mm
rise, and plate_z_tolerance is one-sided at 0.8 mm.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_013DYQe3sx9XDhz59PDHCDNU

2026-08-31 20:55:10 +03:00

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Nozzle XY/Z offset calibration — Klipper port

Source of truth for the sequence: 46-offset-calibration-recovered.md, recovered 2026-08-21 from MIPS machine code with a custom disassembler (annotated .asm listing not in repo).

Design decision (2026-08-21): firmwareExe's JSON is no longer a runtime source. FlashForge's UI cannot use Klipper-side results anyway and HelixScreen is the target, so calibration is stored the way Klipper's own calibrators store theirs — configfile.set() + SAVE_CONFIG — in per-tool sections, modelled on [bed_mesh <profile>] / klipper-toolchanger's [tool Tn].

Files

file	role
`pkgs/klipper/payload/klipper/klippy/extras/ff_tool.py`	`[ff_tool n]`: `dock_x/dock_y` (autosaved by `FF_IMPORT_FIRMWARE_CONFIG`), `nozzle_x/y/z` (measured) and `z_adjust` (user per-tool Z correction, `TOOL_Z_ADJUST`) all autosaved
`pkgs/klipper/payload/klipper/klippy/extras/ff_tool_offset.py`	`TOOL_CALIBRATE_TOOL_OFFSET`, `TOOL_LOCATE_SENSOR`, `TOOL_OFFSET_STATUS`; `[ff_tool_offset]` holds `station_x/y/z` (autosaved) + probe geometry
`pkgs/klipper/payload/klipper/klippy/extras/ff_toolchange.py`	takes docks/offsets from the `ff_tool` objects; `refresh_offsets()`; `_station_z()`; JSON reader and `TOOLCHANGE_RELOAD` removed
`pkgs/klipper/payload/klipper/klippy/extras/ff_legacy.py`	`FF_IMPORT_FIRMWARE_CONFIG [DIR=] [APPLY=1]` — one-shot import of extruder/test/zoffset.json
`pkgs/klipper-config/payload/config/ff-toolchange.cfg`	four deliberately empty `[ff_tool 0..3]` sections + `[ff_toolchange]`. Per-unit values must NOT go here — `SAVE_CONFIG` refuses to autosave an option an include already sets
`pkgs/klipper-config/payload/config/ff-tool-offset.cfg`, `pkgs/klipper-config/payload/config/ff-legacy.cfg`	sections for the other two extras

Storage layout

Everything per-unit lands in printer.cfg's SAVE_CONFIG block. The shipped ff-toolchange.cfg sections stay empty.

# shipped, empty (ff-toolchange.cfg)        # SAVE_CONFIG block of printer.cfg
[ff_tool 1]                                 #*# [ff_tool 1]
                                            #*# dock_x = 296.538940
                                            #*# dock_y = 106.336197
                                            #*# nozzle_x = 16.407789
                                            #*# nozzle_y = 211.986710
                                            #*# nozzle_z = 1.426736
[ff_tool_offset]                            #*# [ff_tool_offset]
#cylinder_x: 28.5                           #*# station_x = 28.791826
                                            #*# station_y = 212.639328
                                            #*# station_z = -1.678819

Raw station-frame absolutes per tool, not T0-relative diffs: recalibrating one tool leaves the others valid; diffs are derived at load (ff_toolchange._derive_offsets).
nozzle_z − station_z is the ~3.19 mm nozzle-to-station-trigger gap the print-start Z offset (the station's own trigger plane, NOT an eddy measurement -- see 46-...md) uses (TOOLCHANGE_SET_PRINT_OFFSET).
Fork constraint (configfile.py:385): SAVE_CONFIG refuses to autosave an option an included file already sets — so nozzle_*/station_* must never be written into the .cfg includes. Autosaving new options into a section that an include defines is fine.
Values are applied live at once; SAVE_CONFIG persists and restarts.
Klipper's babystep is global; TOOL_Z_ADJUST TOOL=n ADJUST=±mm|VALUE=mm [SAVE=1] edits the per-tool z_adjust, re-applies immediately if that tool is mounted, and stages it for SAVE_CONFIG.
[save_variables] is not used (Klipper core never uses it for calibration).

Install / first run

A built package needs none of this — it installs the extras and printer.base.cfg ships the whole ff-*.cfg include block at its end. By hand, onto a printer that is already modded:

cp pkgs/klipper/payload/klipper/klippy/extras/ff_*.py /usr/data/anvil/klipper/klippy/extras/
# Nothing to add to printer.cfg: printer.base.cfg already includes the
# ff-*.cfg set. Section order does not matter.
RESTART
FF_IMPORT_FIRMWARE_CONFIG        ; stages factory dock/nozzle/station
SAVE_CONFIG
TOOLCHANGE_STATUS                ; all four tools calibrated, station_z present
# later, PEI off, homed -- the plate check REFUSES if it is still on:
CALIBRATE_TOOL_OFFSETS
SAVE_CONFIG

ff-legacy.cfg stays included permanently, but only to register the command: since 2026-08-25 the first-boot import is driven from outside klippy by bin/ff-startup.py (once per install, stamped), not by a klippy:ready handler. auto_import / auto_save no longer exist.

Safety on an uncalibrated machine (added 2026-08-21, user request)

START_PRINT calls _FF_PREFLIGHT first, and [ff_print] calls it again through FF_BEFORE_PRINT_START before the file is loaded: no nozzle_z/station_z → refuse before heating/homing/grabbing, with the fix spelled out. Escape hatch for tests: SET_GCODE_VARIABLE MACRO=_FF_JOB VARIABLE=allow_uncalibrated VALUE=1.
TOOL_CALIBRATE_TOOL_OFFSET / TOOL_LOCATE_SENSOR are gated by the plate check, not by an operator flag; default z_target is −3 (the app's station pass-2 value) not −5; once a trigger height is known (calibrated nozzle_z/station_z, or station_z + ~3.25 for a first tool pass) the Z probe stops z_margin (2 mm) below it.
Guards on by default: max_residual 0.5 (4 symmetric points dilute one bad point's error to ~1/4 in the residual while moving the centre by half, so this trips at centre errors of ~1 mm -- a mis-trigger guard, loose enough for the ESTOP's own scatter), gap_min/gap_max 1.5..5 mm for nozzle_z − station_z (3.19 here). A failed guard saves nothing.
TOOL_Z_ADJUST TOOL=n ADJUST=±mm|VALUE=mm [SAVE=1] is the per-tool babystep (Klipper's is global). Live at once; staged for SAVE_CONFIG only on SAVE=1.

Fidelity of the probe sequence

Identical to testEddyExtruderOffsetForwardTwoCheck: start (cylinder_x-12.5, cylinder_y), ESTOP Z TARGET=-5, probes +X +Y -X -Y by 14 mm at zP+0.6 returning through the centre, LS circle fit, lift zP+3, G1 Y; G1 X F2400 to the fit, re-probe Z, second 4-point pass, store pass 2 (cx, cy, zP2) raw. Station: start (cylinder_x, cylinder_y), second Z to -3. M104 S0 T<n> + G1 Z15 on exit. ESTOP is driven by calling the fork's e_stop objects' run_probe() directly (3 samples, error_v spread check, back_v retract — all the fork's).

Deliberate divergences (documented in the cfg): accel stays 100 for the whole run and is restored to the pre-run limit; optional max_residual/min_radius/max_radius guards; pass-2 points use the 3-decimal-rounded centre actually commanded; fit_circle is the centroid-shifted fitCircleStable (identical result for 4 axis-aligned points); homing is required, not done.

Verified (mock harness, not in repo)

Emitted G-code order matches the recovered list; fitted centre = virtual centre; autosave receives exactly nozzle_x/y/z for the calibrated tool and station_x/y/z; live offsets update without restart; TOOLCHANGE_SET_PRINT_OFFSET gives 3.240 for T0/220 °C/80 °C/0.25 mm (the value in docs/notes/40-offsets.md) and refuses without station_z; TOOL_Z_ADJUST applies live and stages only on SAVE=1; plate check, bounded Z target, gap and residual guards all fire; FF_IMPORT_FIRMWARE_CONFIG against live/firmwareRes-config stages 15 values and reproduces the offset table in docs/notes/40-offsets.md. Not yet run on the printer.

Not recoverable / open

fitCircleByLeastSquares body not traced line by line; TypeManager=6 in the station pass unnamed; what feature of the empty carriage the station detects (12.4 mm +X of the nozzle, 3.2 mm lower) is inferred from the numbers only.

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