ouch finger

include/thermal_controller.h

@@ -456,7 +456,7 @@ private:
 
   void updateAutotune(float avgTempC, float maxTempC, uint32_t nowMs) {
     float duty = 0.0f;
-    uint8_t fan = AUTOTUNE_PREHEAT_FAN_PWM;
+    uint8_t fan = stirFanPwm_;
     autotuner_.update(avgTempC, maxTempC, cornerSpreadC_, nowMs, duty, fan);
 
     heaterDutyPercent_ = duty;
@@ -464,7 +464,7 @@ private:
     heaterOn_ = duty >= 50.0f;
     digitalWrite(HEATER_PIN, heaterOn_ ? HIGH : LOW);
     heaterBlock_ = duty > 0.0f ? HeaterBlock::None : HeaterBlock::Autotune;
-    writeFan(fan);
+    writeFan(fanManualActive_ ? fanManualPwm_ : stirFanPwm_);
     lastHeaterUpdateMs_ = nowMs;
     commitAutotuneIfDone();
   }
@@ -513,15 +513,7 @@ private:
     }
     heaterDutyPercent_ = applyHeaterRamp(duty, avgTempC, nowMs);
 
-    const uint8_t fanPwm = fanManualActive_ ? fanManualPwm_ : stirFanPwm_;
-    regulatingFanPwm_ = fanWithMinStir(avgTempC, fanPwm);
-  }
-
-  uint8_t fanWithMinStir(float avgTempC, uint8_t pwm) const {
-    if (avgTempC < IDLE_AUTO_FAN_OFF_TEMP_C) {
-      return 0;
-    }
-    return pwm;
+    regulatingFanPwm_ = fanManualActive_ ? fanManualPwm_ : stirFanPwm_;
   }
 
   static float clampPercent(float value) {
@@ -547,6 +539,11 @@ private:
 
   float allowanceFromMaxCorner(float maxTempC, float avgTempC) const {
     if (!shouldLimitMaxCorner(avgTempC)) {
+      // Heat-up: only taper when a hot corner nears the emergency ceiling
+      if (maxTempC >= EMERGENCY_MAX_TEMP_C - 3.0f) {
+        const float headroom = EMERGENCY_MAX_TEMP_C - maxTempC;
+        return clampPercent((headroom / 3.0f) * 100.0f);
+      }
       return 100.0f;
     }