Implemented a least squares fit of the bed equation for auto bed leveling.

The code for the LSQ solver (qr_solve) is copyrighted by John Burkardt and released under LGPL here:
http://people.sc.fsu.edu/~%20jburkardt/c_src/qr_solve/qr_solve.html
(see qr_solve.cpp for further copyright information)

Marlin/Configuration.h

@@ -366,6 +366,15 @@ const bool Z_MAX_ENDSTOP_INVERTING = true; // set to true to invert the logic of
     
   #endif
   
+  // with accurate bed leveling, the bed is sampled in a ACCURATE_BED_LEVELING_POINTSxACCURATE_BED_LEVELING_POINTS grid and least squares solution is calculated
+  // Note: this feature occupies 10'206 byte
+  #define ACCURATE_BED_LEVELING
+  
+  #ifdef ACCURATE_BED_LEVELING
+     // I wouldn't see a reason to go above 3 (=9 probing points on the bed)
+    #define ACCURATE_BED_LEVELING_POINTS 2
+  #endif
+  
 #endif
 
 

Marlin/Marlin_main.cpp

@@ -31,6 +31,9 @@
 
 #ifdef ENABLE_AUTO_BED_LEVELING
 #include "vector_3.h"
+  #ifdef ACCURATE_BED_LEVELING
+    #include "qr_solve.h"
+  #endif
 #endif // ENABLE_AUTO_BED_LEVELING
 
 #include "ultralcd.h"
@@ -798,6 +801,35 @@ static void axis_is_at_home(int axis) {
 }
 
 #ifdef ENABLE_AUTO_BED_LEVELING
+#ifdef ACCURATE_BED_LEVELING
+static void set_bed_level_equation_lsq(double *plane_equation_coefficients)
+{
+    vector_3 planeNormal = vector_3(-plane_equation_coefficients[0], -plane_equation_coefficients[1], 1);
+    planeNormal.debug("planeNormal");
+    plan_bed_level_matrix = matrix_3x3::create_look_at(planeNormal);
+    //bedLevel.debug("bedLevel");
+
+    plan_bed_level_matrix.debug("bed level before");
+    //vector_3 uncorrected_position = plan_get_position_mm();
+    //uncorrected_position.debug("position before");
+
+    // and set our bed level equation to do the right thing
+//    plan_bed_level_matrix = matrix_3x3::create_inverse(bedLevel);
+//    plan_bed_level_matrix.debug("bed level after");
+
+    vector_3 corrected_position = plan_get_position();
+//    corrected_position.debug("position after");
+    current_position[X_AXIS] = corrected_position.x;
+    current_position[Y_AXIS] = corrected_position.y;
+    current_position[Z_AXIS] = corrected_position.z;
+
+    // but the bed at 0 so we don't go below it.
+    current_position[Z_AXIS] = -Z_PROBE_OFFSET_FROM_EXTRUDER; // in the lsq we reach here after raising the extruder due to the loop structure
+
+    plan_set_position(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS], current_position[E_AXIS]);
+}
+
+#else
 static void set_bed_level_equation(float z_at_xLeft_yFront, float z_at_xRight_yFront, float z_at_xLeft_yBack) {
     plan_bed_level_matrix.set_to_identity();
 
@@ -832,6 +864,7 @@ static void set_bed_level_equation(float z_at_xLeft_yFront, float z_at_xRight_yF
 
     plan_set_position(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS], current_position[E_AXIS]);
 }
+#endif // ACCURATE_BED_LEVELING
 
 static void run_z_probe() {
     plan_bed_level_matrix.set_to_identity();
@@ -1320,7 +1353,82 @@ void process_commands()
             setup_for_endstop_move();
 
             feedrate = homing_feedrate[Z_AXIS];
-
+#ifdef ACCURATE_BED_LEVELING
+            
+            int xGridSpacing = (RIGHT_PROBE_BED_POSITION - LEFT_PROBE_BED_POSITION) / (ACCURATE_BED_LEVELING_POINTS-1);
+            int yGridSpacing = (BACK_PROBE_BED_POSITION - FRONT_PROBE_BED_POSITION) / (ACCURATE_BED_LEVELING_POINTS-1);
+            
+            
+            // solve the plane equation ax + by + d = z
+            // A is the matrix with rows [x y 1] for all the probed points
+            // B is the vector of the Z positions
+            // the normal vector to the plane is formed by the coefficients of the plane equation in the standard form, which is Vx*x+Vy*y+Vz*z+d = 0
+            // so Vx = -a Vy = -b Vz = 1 (we want the vector facing towards positive Z
+            
+            // "A" matrix of the linear system of equations
+            double eqnAMatrix[ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS*3];
+            // "B" vector of Z points
+            double eqnBVector[ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS];
+            
+            
+            int probePointCounter = 0;
+            
+            for (int xProbe=LEFT_PROBE_BED_POSITION; xProbe <= RIGHT_PROBE_BED_POSITION; xProbe += xGridSpacing)
+            {
+              for (int yProbe=FRONT_PROBE_BED_POSITION; yProbe <= BACK_PROBE_BED_POSITION; yProbe += yGridSpacing)
+              {
+                if (probePointCounter == 0)
+                {
+                  // raise before probing
+                  do_blocking_move_to(current_position[X_AXIS], current_position[Y_AXIS], Z_RAISE_BEFORE_PROBING);
+                } else
+                {               
+                  // raise extruder
+                  do_blocking_move_to(current_position[X_AXIS], current_position[Y_AXIS], current_position[Z_AXIS] + Z_RAISE_BETWEEN_PROBINGS);
+                }
+                
+                
+                do_blocking_move_to(xProbe - X_PROBE_OFFSET_FROM_EXTRUDER, yProbe - Y_PROBE_OFFSET_FROM_EXTRUDER, current_position[Z_AXIS]);
+    
+                engage_z_probe();   // Engage Z Servo endstop if available
+                run_z_probe();
+                eqnBVector[probePointCounter] = current_position[Z_AXIS];
+                retract_z_probe();
+    
+                SERIAL_PROTOCOLPGM("Bed x: ");
+                SERIAL_PROTOCOL(xProbe);
+                SERIAL_PROTOCOLPGM(" y: ");
+                SERIAL_PROTOCOL(yProbe);
+                SERIAL_PROTOCOLPGM(" z: ");
+                SERIAL_PROTOCOL(current_position[Z_AXIS]);
+                SERIAL_PROTOCOLPGM("\n");
+                
+                eqnAMatrix[probePointCounter + 0*ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS] = xProbe;
+                eqnAMatrix[probePointCounter + 1*ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS] = yProbe;
+                eqnAMatrix[probePointCounter + 2*ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS] = 1;
+                probePointCounter++;
+              }
+            }
+            clean_up_after_endstop_move();
+            
+            // solve lsq problem
+            double *plane_equation_coefficients = qr_solve(ACCURATE_BED_LEVELING_POINTS*ACCURATE_BED_LEVELING_POINTS, 3, eqnAMatrix, eqnBVector);
+            
+            SERIAL_PROTOCOLPGM("Eqn coefficients: a: ");
+            SERIAL_PROTOCOL(plane_equation_coefficients[0]);
+            SERIAL_PROTOCOLPGM(" b: ");
+            SERIAL_PROTOCOL(plane_equation_coefficients[1]);
+            SERIAL_PROTOCOLPGM(" d: ");
+            SERIAL_PROTOCOLLN(plane_equation_coefficients[2]);
+            
+            
+            set_bed_level_equation_lsq(plane_equation_coefficients);
+            
+            free(plane_equation_coefficients);
+            
+#else // ACCURATE_BED_LEVELING not defined
+            
+            
             // prob 1
             do_blocking_move_to(current_position[X_AXIS], current_position[Y_AXIS], Z_RAISE_BEFORE_PROBING);
             do_blocking_move_to(LEFT_PROBE_BED_POSITION - X_PROBE_OFFSET_FROM_EXTRUDER, BACK_PROBE_BED_POSITION - Y_PROBE_OFFSET_FROM_EXTRUDER, current_position[Z_AXIS]);
@@ -1376,7 +1484,9 @@ void process_commands()
             clean_up_after_endstop_move();
 
             set_bed_level_equation(z_at_xLeft_yFront, z_at_xRight_yFront, z_at_xLeft_yBack);
-
+         
+            
+#endif // ACCURATE_BED_LEVELING
             st_synchronize();            
 
             // The following code correct the Z height difference from z-probe position and hotend tip position.

Marlin/qr_solve.h

@@ -0,0 +1,22 @@
+#include "Configuration.h"
+
+#ifdef ACCURATE_BED_LEVELING
+
+void daxpy ( int n, double da, double dx[], int incx, double dy[], int incy );
+double ddot ( int n, double dx[], int incx, double dy[], int incy );
+double dnrm2 ( int n, double x[], int incx );
+void dqrank ( double a[], int lda, int m, int n, double tol, int *kr, 
+  int jpvt[], double qraux[] );
+void dqrdc ( double a[], int lda, int n, int p, double qraux[], int jpvt[], 
+  double work[], int job );
+int dqrls ( double a[], int lda, int m, int n, double tol, int *kr, double b[], 
+  double x[], double rsd[], int jpvt[], double qraux[], int itask );
+void dqrlss ( double a[], int lda, int m, int n, int kr, double b[], double x[], 
+  double rsd[], int jpvt[], double qraux[] );
+int dqrsl ( double a[], int lda, int n, int k, double qraux[], double y[], 
+  double qy[], double qty[], double b[], double rsd[], double ab[], int job );
+void dscal ( int n, double sa, double x[], int incx );
+void dswap ( int n, double x[], int incx, double y[], int incy );
+double *qr_solve ( int m, int n, double a[], double b[] );
+
+#endif