Request for possible "stallguard" for clogs

Features
1

I got the idea for a stallguard implementation, where it will use how stallguard works, but to use for clogs as well/instead for extruder motor.

Is this something that could be feasible?

Had GPT hallucinate a possible way to achieve this. Thoughts?

Step-by-Step Implementation

  1. Configure the Extruder Stepper for Stall Detection

Update the [extruder] section in your Klipper config to include the stall detection parameters.

[extruder]
step_pin: ...
dir_pin: ...
enable_pin: ...
microsteps: 16
rotation_distance: ...
gear_ratio: ...
pressure_advance: ...
stepper_motor:
  driver_SGTHRS: 50  # Adjust to find clog-detection threshold
  diag1_pin: PA1      # Replace with your actual diag1 pin

driver_SGTHRS: Set this value higher for clog-like loads. Start with 50 (or lower if it’s not detecting resistance properly).

diag1_pin: This is the pin that receives the stall signal from the driver.

  1. Create a Macro for Emergency Handling
    Set up a macro to trigger when the extruder stall is detected.
[gcode_macro EXTRUDER_STALL_HANDLER]
description: "Handles extruder stall due to excessive force"
gcode:
  M118 Detected extruder stall! Taking action...
  PAUSE  # Pause the print
  M118 Homing axes...
  G28    # Home all axes
  M118 Clearing issue...
  # Optionally: Unload or move filament back
  M83
  G1 E-5 F300  # Retract filament slightly
  1. Add Background Monitoring
    Use a delayed_gcode to continuously monitor the extruder’s stall status.
[delayed_gcode CHECK_EXTRUDER_STALL]
gcode:
  {% if printer.extruder.stall_detected %}
    EXTRUDER_STALL_HANDLER
  {% endif %}
  UPDATE_DELAYED_GCODE ID=CHECK_EXTRUDER_STALL DURATION=0.1

This will check for stall conditions every 0.1 seconds during the print.

  1. Calibrate Stall Threshold
    The SGTHRS value must be carefully calibrated:

Start with a high value (less sensitive) and lower it incrementally until it detects realistic clogging conditions.
Test by manually blocking the filament or creating high resistance in the extruder and observing behavior.

Testing and Validation
Simulate Clogs:

Block the nozzle or filament path while extruding to ensure the driver detects the stall.
Verify that the macro triggers correctly and halts the print.
Fine-Tune Parameters:

Adjust SGTHRS to prevent false positives (e.g., from normal extrusion pressure changes).
Test across different filaments and temperatures, as extrusion force varies.
Safety Checks:

Confirm that the recovery actions (e.g., homing, retracting) work smoothly without damaging the printer or filament path.

Optional Enhancements
Adaptive Sensitivity: Use a lower SGTHRS during slow extrusion (e.g., first layers) and a higher value during fast extrusion.

Filament Load Management: Include steps to unload filament automatically if a clog is detected.

Logging and Alerts: Use M118 or Klipper’s built-in logging to record when stalls occur, or trigger an external notification via OctoPrint.