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fix: H2C carousel - port BBS NozzleStatusRecorder for per-slot purge tracking (#14800)

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## Problem

On H2C (carousel) printers, the wipe tower purge volume calculation in
`_make_wipe_tower()` tracks filament state **per-extruder** (2 slots).
Since H2C has up to 7 carousel nozzle slots on a single extruder, all
filaments sharing that extruder are collapsed into one tracking slot.
This causes:

Test:

[5cubes.3mf.zip](https://github.com/user-attachments/files/30092551/5cubes.3mf.zip)

- **Massive redundant AMS flushing** every filament change on the
carousel triggers a full purge against the "previous" filament, even
when the target nozzle slot already has the correct filament loaded
- **60.9g total weight** instead of ~17g (**3.5× material waste**)
- **3h09m print time** instead of ~1h57m (**60% longer**)

## Root Cause

The code uses `nozzle_cur_filament_ids[extruder_id]` (a 2-element array)
to track which filament was last used for each extruder. BambuStudio
uses `NozzleStatusRecorder`, which tracks per `group_id` (physical
carousel slot 0..6).

## Changes

| File | Change |
|---|---|
| `Print.cpp` | Replace `nozzle_cur_filament_ids` with
`NozzleStatusRecorder`. Use `get_nozzle_for_filament()` to resolve the
physical carousel slot per layer. Select `filament_prime_volume_nc` for
nozzle changes, `filament_prime_volume` for filament changes. |
| `PrintConfig.hpp` | Add `ConfigOptionFloats filament_prime_volume`
(per-filament EC prime volume, missing from upstream but present in BBS
and H2C profiles) |
| `PrintConfig.cpp` | Register `filament_prime_volume` with default
45mm³ (matching BBS) |
| `Preset.cpp` | Add `filament_prime_volume` to preset keys |

Also includes `tests/compare_analyzer/` - two standalone Python tools
for G-code slice comparison and temperature timeline analysis (stdlib
only, no dependencies).

## Test Results (5-color H2C Hybrid print, same 3mf project)

| Metric | Upstream (broken) | **Fixed** | BBS (reference) |
|---|---|---|---|
| **Total weight** | 60.90g | **16.20g** ✅ | 17.47g |
| **Print time** | 3h09m | **1h57m** ✅ | 1h51m |
| **Filament changes** | 105 | 105 | 140 |
| **Tool changes** | 35 | 35 | 35 |
| **Critical discrepancies vs BBS** | ⚠️ YES | ✅ None | — |


## Analysis Tools (`tests/compare_analyzer/`)

Two standalone Python tools (stdlib only, no dependencies) for deep
G-code comparison:

- **`compare_slices.py`** - comprehensive .3mf slice comparison:
filament usage, nozzle mapping, tool change sequences, prime tower
analysis, temperature timeline, retract parameters, and automatic
critical discrepancy detection (weight/time anomalies)
- **`show_temp_plot.py`** - interactive HTML temperature timeline
plotter for visualising heater profiles during multi-nozzle prints
(supports single-file and side-by-side comparison)

Usage:
```bash
python3 tests/compare_analyzer/compare_slices.py file1.3mf file2.3mf --labels "Upstream" "Fixed"
python3 tests/compare_analyzer/show_temp_plot.py file1.3mf file2.3mf
```


## Screenshots

### OrcaSlicer Upstream (unfixed) - 60.90g, 3h09m
<img width="1512" height="982" alt="Screenshot 2026-07-16 at 15 22 58"
src="https://github.com/user-attachments/assets/3efb2bff-ff1e-43db-9669-feafa5921b51"
/>


### OrcaSlicer Fixed - 16.20g, 1h57m
<img width="1512" height="982" alt="Screenshot 2026-07-16 at 15 23 08"
src="https://github.com/user-attachments/assets/c1d36dc5-9b01-4691-80ef-7364540e1f4e"
/>

### BambuStudio Reference - 17.47g, 1h51m
<img width="1512" height="982" alt="Screenshot 2026-07-16 at 15 24 52"
src="https://github.com/user-attachments/assets/5c0b11e2-64f4-40e9-8c7c-3f42519786c3"
/>

### Temperature Timeline: Upstream vs Fixed
<img width="1511" height="829" alt="Screenshot 2026-07-16 at 15 23 35"
src="https://github.com/user-attachments/assets/926c2cb5-dfd4-4ce0-bb40-82e6165eb134"
/>


### Temperature Timeline: Fixed vs BBS

<img width="1512" height="825" alt="Screenshot 2026-07-16 at 15 23 51"
src="https://github.com/user-attachments/assets/85c72dda-e779-4aa6-8118-fb17e5f8482d"
/>


## Compatibility

Safe for non-carousel printers: when each extruder has a single nozzle,
`group_id == extruder_id`, so `NozzleStatusRecorder` behaves identically
to the original per-extruder tracking. The `filament_prime_volume`
default (45mm³) matches the existing global `prime_volume` default.

## Reference
BambuStudio `Print.cpp` `_make_wipe_tower()` L3341-3392 -
`NozzleStatusRecorder` pattern.
This commit is contained in:
SoftFever
2026-07-22 12:59:17 +08:00
committed by GitHub
parent b292a06b3f 203ae1588e
commit 7db0a59cc1
13 changed files with 3300 additions and 47 deletions
Download Patch File Download Diff File Expand all files Collapse all files

104
src/libslic3r/Print.cpp
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@@ -4018,6 +4018,8 @@ void Print::_make_wipe_tower()
m_wipe_tower_data.tool_ordering.empty() ? 0.f : m_wipe_tower_data.tool_ordering.back().print_z, m_wipe_tower_data.tool_ordering.all_extruders());
wipe_tower.set_has_tpu_filament(this->has_tpu_filament());
wipe_tower.set_filament_map(this->get_filament_maps());
// Vortek H2C: pass nozzle-level map for carousel rotation detection in tool_change_new()
wipe_tower.set_filament_nozzle_map(this->get_filament_nozzle_maps());
// Feed the has_filament_switcher device flag (develop-only dynamic key, read defensively from
// the full config — no shipping profile sets it) and the shared printable bed used by the PETG
// pre-extrusion offset clamp. Both are inert unless has_filament_switcher is set.
@@ -4053,14 +4055,32 @@ void Print::_make_wipe_tower()
multi_extruder_flush.emplace_back(wipe_volumes);
}
std::vector<int>filament_maps = get_filament_maps();
// Use NozzleStatusRecorder for per-carousel-slot tracking (BBS pattern).
// The original Orca code tracked per-extruder (2 slots), which collapsed all
// carousel filaments into one slot and caused massive redundant AMS flushing.
auto group_result = get_layered_nozzle_group_result();
MultiNozzleUtils::NozzleStatusRecorder nozzle_recorder;
// Fallback (group_result == null) per-physical-nozzle tracking, matching the original
// pre-port behavior: remembers the last filament loaded in each physical nozzle slot.
std::vector<unsigned int> nozzle_cur_filament_ids(nozzle_nums, (unsigned int) -1);
std::vector<int>filament_maps = get_filament_maps();
int layer_idx = -1;
std::vector<unsigned int> nozzle_cur_filament_ids(nozzle_nums, -1);
unsigned int current_filament_id = m_wipe_tower_data.tool_ordering.first_extruder();
size_t cur_nozzle_id = filament_maps[current_filament_id] - 1;
nozzle_cur_filament_ids[cur_nozzle_id] = current_filament_id;
// Initialize NozzleStatusRecorder with the first filament's carousel slot
if (group_result) {
auto nozzle = group_result->get_nozzle_for_filament(current_filament_id, layer_idx);
if (nozzle)
nozzle_recorder.set_nozzle_status(nozzle->group_id, current_filament_id, nozzle->extruder_id);
} else {
size_t cur_nozzle_id = filament_maps[current_filament_id] - 1;
nozzle_cur_filament_ids[cur_nozzle_id] = current_filament_id;
}
for (auto& layer_tools : m_wipe_tower_data.tool_ordering.layer_tools()) { // for all layers
++layer_idx;
if (!layer_tools.has_wipe_tower) continue;
bool first_layer = &layer_tools == &m_wipe_tower_data.tool_ordering.front();
wipe_tower.plan_toolchange((float)layer_tools.print_z, (float)layer_tools.wipe_tower_layer_height, current_filament_id, current_filament_id);
@@ -4071,30 +4091,76 @@ void Print::_make_wipe_tower()
if (filament_id == current_filament_id)
continue;
int nozzle_id = filament_maps[filament_id] - 1;
unsigned int pre_filament_id = nozzle_cur_filament_ids[nozzle_id];
float volume_to_purge = 0;
if (pre_filament_id != (unsigned int)(-1) && pre_filament_id != filament_id) {
volume_to_purge = multi_extruder_flush[nozzle_id][pre_filament_id][filament_id];
// Fast purge mode uses flush_multiplier_fast; Default is inert.
float flush_multiplier = (m_config.prime_volume_mode == PrimeVolumeMode::pvmFast) ? m_config.flush_multiplier_fast.get_at(nozzle_id)
: m_config.flush_multiplier.get_at(nozzle_id);
volume_to_purge *= flush_multiplier;
volume_to_purge = pre_filament_id == -1 ? 0 :
layer_tools.wiping_extrusions().mark_wiping_extrusions(*this, current_filament_id, filament_id, volume_to_purge);
// Per-carousel-slot purge tracking via NozzleStatusRecorder
if (group_result) {
auto nozzle_info = group_result->get_nozzle_for_filament(filament_id, layer_idx);
if (nozzle_info) {
int extruder_id = nozzle_info->extruder_id;
int nozzle_id = nozzle_info->group_id;
int prev_nozzle_filament = nozzle_recorder.get_filament_in_nozzle(nozzle_id);
if (!nozzle_recorder.is_nozzle_empty(nozzle_id) &&
static_cast<int>(filament_id) != prev_nozzle_filament) {
volume_to_purge = multi_extruder_flush[extruder_id][prev_nozzle_filament][filament_id];
// Fast purge mode uses flush_multiplier_fast; Default is inert.
float flush_multiplier = (m_config.prime_volume_mode == PrimeVolumeMode::pvmFast)
? m_config.flush_multiplier_fast.get_at(extruder_id)
: m_config.flush_multiplier.get_at(extruder_id);
volume_to_purge *= flush_multiplier;
volume_to_purge = layer_tools.wiping_extrusions().mark_wiping_extrusions(
*this, current_filament_id, filament_id, volume_to_purge);
}
nozzle_recorder.set_nozzle_status(nozzle_id, filament_id, extruder_id);
}
} else {
// Fallback: original Orca per-physical-nozzle path (non-carousel printers).
// Flush source is the last filament that occupied THIS nozzle, guarded so the
// first use of a nozzle incurs no flush.
int nozzle_id = filament_maps[filament_id] - 1;
unsigned int pre_filament_id = nozzle_cur_filament_ids[nozzle_id];
if (pre_filament_id != (unsigned int) -1 && pre_filament_id != filament_id) {
volume_to_purge = multi_extruder_flush[nozzle_id][pre_filament_id][filament_id];
float flush_multiplier = (m_config.prime_volume_mode == PrimeVolumeMode::pvmFast)
? m_config.flush_multiplier_fast.get_at(nozzle_id)
: m_config.flush_multiplier.get_at(nozzle_id);
volume_to_purge *= flush_multiplier;
volume_to_purge = layer_tools.wiping_extrusions().mark_wiping_extrusions(
*this, current_filament_id, filament_id, volume_to_purge);
}
nozzle_cur_filament_ids[nozzle_id] = filament_id;
}
//During the filament change, the extruder will extrude an extra length of grab_length for the corresponding detection, so the purge can reduce this length.
float grab_purge_volume = m_config.grab_length.get_at(nozzle_id) * 2.4; //(diameter/2)^2*PI=2.4
int grab_extruder_id = filament_maps[filament_id] - 1;
float grab_purge_volume = m_config.grab_length.get_at(grab_extruder_id) * 2.4; //(diameter/2)^2*PI=2.4
volume_to_purge = std::max(0.f, volume_to_purge - grab_purge_volume);
// Saving mode reduces the prime volume to 15 mm3; Default is inert.
float prime_volume = (m_config.prime_volume_mode == PrimeVolumeMode::pvmSaving) ? 15.f : (float) m_config.prime_volume;
// Select prime volume per-filament: nozzle change (carousel rotation) uses
// filament_prime_volume_nc, filament change (same nozzle slot) uses filament_prime_volume.
float wipe_volume_ec = filament_id < m_config.filament_prime_volume.values.size()
? m_config.filament_prime_volume.values[filament_id]
: (float) m_config.prime_volume;
float wipe_volume_nc = filament_id < m_config.filament_prime_volume_nc.values.size()
? m_config.filament_prime_volume_nc.values[filament_id]
: (float) m_config.prime_volume;
float prime_volume = wipe_volume_ec;
if (group_result) {
bool is_nozzle_change = group_result->are_filaments_same_extruder(current_filament_id, filament_id, layer_idx) &&
!group_result->are_filaments_same_nozzle(current_filament_id, filament_id, layer_idx);
if (is_nozzle_change) {
prime_volume = wipe_volume_nc;
}
}
if (m_config.prime_volume_mode == PrimeVolumeMode::pvmSaving) {
prime_volume = 15.f;
}
wipe_tower.plan_toolchange((float)layer_tools.print_z, (float)layer_tools.wipe_tower_layer_height, current_filament_id, filament_id,
prime_volume, volume_to_purge);
current_filament_id = filament_id;
nozzle_cur_filament_ids[nozzle_id] = filament_id;
}
layer_tools.wiping_extrusions().ensure_perimeters_infills_order(*this);