Do a hard kill for failed homing moves (#11160)

Marlin/Marlin_main.cpp

@@ -2242,7 +2242,6 @@ void clean_up_after_endstop_or_probe_move() {
       if (probe_triggered && set_bltouch_deployed(false)) return true;
     #endif
 
-    // Clear endstop flags
     endstops.hit_on_purpose();
 
     // Get Z where the steppers were interrupted
@@ -2989,6 +2988,7 @@ static void do_homing_move(const AxisEnum axis, const float distance, const floa
   // Tell the planner the axis is at 0
   current_position[axis] = 0;
 
+  // Do the move, which is required to hit an endstop
   #if IS_SCARA
     SYNC_PLAN_POSITION_KINEMATIC();
     current_position[axis] = distance;
@@ -3015,7 +3015,7 @@ static void do_homing_move(const AxisEnum axis, const float distance, const floa
       #endif
     }
 
-    endstops.hit_on_purpose();
+    endstops.validate_homing_move();
 
     // Re-enable stealthChop if used. Disable diag1 pin on driver.
     #if ENABLED(SENSORLESS_HOMING)
@@ -3725,7 +3725,9 @@ inline void gcode_G4() {
     #endif
 
     do_blocking_move_to_xy(1.5 * mlx * x_axis_home_dir, 1.5 * mly * home_dir(Y_AXIS), fr_mm_s);
-    endstops.hit_on_purpose(); // clear endstop hit flags
+
+    endstops.validate_homing_move();
+
     current_position[X_AXIS] = current_position[Y_AXIS] = 0.0;
 
     #if ENABLED(SENSORLESS_HOMING)
@@ -3905,7 +3907,7 @@ inline void gcode_G4() {
    * A delta can only safely home all axes at the same time
    * This is like quick_home_xy() but for 3 towers.
    */
-  inline bool home_delta() {
+  inline void home_delta() {
     #if ENABLED(DEBUG_LEVELING_FEATURE)
       if (DEBUGGING(LEVELING)) DEBUG_POS(">>> home_delta", current_position);
     #endif
@@ -3929,16 +3931,7 @@ inline void gcode_G4() {
       delta_sensorless_homing(false);
     #endif
 
-    // If an endstop was not hit, then damage can occur if homing is continued.
-    // This can occur if the delta height not set correctly.
-    if (!(endstops.trigger_state() & (_BV(X_MAX) | _BV(Y_MAX) | _BV(Z_MAX)))) {
-      LCD_MESSAGEPGM(MSG_ERR_HOMING_FAILED);
-      SERIAL_ERROR_START();
-      SERIAL_ERRORLNPGM(MSG_ERR_HOMING_FAILED);
-      return false;
-    }
-
-    endstops.hit_on_purpose(); // clear endstop hit flags
+    endstops.validate_homing_move();
 
     // At least one carriage has reached the top.
     // Now re-home each carriage separately.
@@ -3957,8 +3950,6 @@ inline void gcode_G4() {
     #if ENABLED(DEBUG_LEVELING_FEATURE)
       if (DEBUGGING(LEVELING)) DEBUG_POS("<<< home_delta", current_position);
     #endif
-
-    return true;
   }
 
 #endif // DELTA
@@ -5514,12 +5505,10 @@ void home_all_axes() { gcode_G28(true); }
 
   float lcd_probe_pt(const float &rx, const float &ry);
 
-  bool ac_home() {
+  void ac_home() {
     endstops.enable(true);
-    if (!home_delta())
-      return false;
+    home_delta();
     endstops.not_homing();
-    return true;
   }
 
   void ac_setup(const bool reset_bed) {
@@ -5972,8 +5961,7 @@ void home_all_axes() { gcode_G28(true); }
 
     ac_setup(!_0p_calibration && !_1p_calibration);
 
-    if (!_0p_calibration)
-      if (!ac_home()) return;
+    if (!_0p_calibration) ac_home();
 
     do { // start iterations
 
@@ -6166,7 +6154,7 @@ void home_all_axes() { gcode_G28(true); }
           sprintf_P(&mess[15], PSTR("%03i.x"), (int)round(zero_std_dev));
         lcd_setstatus(mess);
       }
-      if (!ac_home()) return;
+      ac_home();
     }
     while (((zero_std_dev < test_precision && iterations < 31) || iterations <= force_iterations) && zero_std_dev > calibration_precision);
 

Marlin/endstops.cpp

@@ -229,6 +229,12 @@ void Endstops::not_homing() {
   #endif
 }
 
+// If the last move failed to trigger an endstop, call kill
+void Endstops::validate_homing_move() {
+  if (!trigger_state()) kill(PSTR(MSG_ERR_HOMING_FAILED));
+  hit_on_purpose();
+}
+
 // Enable / disable endstop z-probe checking
 #if HAS_BED_PROBE
   void Endstops::enable_z_probe(const bool onoff) {

Marlin/endstops.h

@@ -143,6 +143,9 @@ class Endstops {
     // Disable / Enable endstops based on ENSTOPS_ONLY_FOR_HOMING and global enable
     static void not_homing();
 
+    // If the last move failed to trigger an endstop, call kill
+    static void validate_homing_move();
+
     // Clear endstops (i.e., they were hit intentionally) to suppress the report
     FORCE_INLINE static void hit_on_purpose() { hit_state = 0; }