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Prove the M101 dose-model switch; record the judged dose curves

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The stream harness gains rules 18 to 21: the floor is derived from the
selected model's config key at the arm and a typed $35 is overwritten;
M101 switches the rendering exactly at the boundary in both directions
with no continuous FIRE at full duty across it; a refused switch (the
spindle on) leaves the stream unchanged, and the harness resyncs with
an empty line because the core skips G-code after an error until the
sender resyncs; M2 reverts a program-scoped switch and Q1 holds. The
analog sessions pin laser_floor_analog at the density floor so the
existing duty expectations stand, and the density ladder's unfloored
run moves from a chained $35 write to the laser_floor_density key.

The catalog's laser.power-floor becomes model-aware: it reads the
configured model and the floor keys from forgectrl, switches to the
configured model with M101 so the derivation runs without a fire, and
expects $35 to be that model's floor. The new laser.power-model-switch
switches to each model with the spindle off, checks the reported
message and $35 after each switch, and checks the M2 revert. The new
mswitch bench drill runs the switch on the machine in one armed run.

Docs follow: BRINGUP's Laser control section describes the switch, the
derived floors and the measured dose response of both models; the
MOTION settings table gains the five keys; LIGHTBURN gains a Power
models section and drops the stale 30 percent floor advice; SAFETY
names the switch's refusal rule; the CAMPAIGN-LOG records the judged
depth-witness runs of 2026-08-30 and the switch's host and bench proof.
This commit is contained in:
ScottW514
2026-08-30 15:08:34 -04:00
parent f88c7784d4
commit 3025996c86
9 changed files with 684 additions and 87 deletions
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scripts/bench/laser_stream_test.py
+282 -18
View File
@@ -58,6 +58,21 @@ over TCP, then checks the dumps against the kernel feeder contract:
the M3 that opens the next job is the only thing that can light its
first move - set_state must push the whole state, fire included,
never the duty alone
18. the floor is derived, never typed: $35 is loaded from the selected
model's floor key (laser_floor_density / laser_floor_analog) at
the arm, so a $35 typed by the sender is overwritten - the ladder
renders through the key's floor, and the arm report names the
model and the floor in force
19. M101 switches the model at a boundary and nowhere else: with the
spindle off and the controller idle, the rendering changes exactly
at the switch (analog duties before, pinned full duty and dithered
FIRE after, or the reverse) and there is no torn transition - no
window of continuous FIRE at full duty anywhere across it
20. M101 is refused with the spindle on (error 253, the reason
reported), and the stream is unchanged by the refusal
21. a switch is program-scoped: M2 reverts it to the boot default and
the next job renders under the default, while M101 ... Q1 sticks
across M2
Usage: laser_stream_test.py [path-to-binary] (default ./build-native/grblHAL_glowforge)
"""
@@ -153,16 +168,99 @@ JOB_LADDER.append("M5")
# the floor exists only to keep an analog duty out of the tube's dead
# band - under density every pulse is full-power, and a floor would just
# clamp the light end of the range.
ANALOG_CONF = "laser_power_model = analog\n"
# The floors are config keys, loaded into $35 at every arm (rule 18).
# The analog sessions pin theirs at the board's density floor so the
# duty expectations above hold unchanged; the analog default is the
# tube's lasing duty (16), covered by the switch sessions below.
ANALOG_FLOOR_DEFAULT_PCT = 16.0
ANALOG_CONF = ("laser_power_model = analog\n"
"laser_floor_analog = %g\n" % PWM_MIN_PCT)
DENSITY_PERIOD = 20
DENSITY_MIN_TICKS = 3
DENSITY_CONF_BASE = ("laser_pulse_ticks = %d\n"
"laser_pulse_min_ticks = %d\n"
% (DENSITY_PERIOD, DENSITY_MIN_TICKS))
# The density ladder runs unfloored: the floor exists only to keep an
# analog duty out of the tube's dead band, and here it would just clamp
# the light end of the range. A floor of 0 is honored as written.
DENSITY_CONF = ("laser_power_model = density\n"
"laser_pulse_ticks = %d\n"
"laser_pulse_min_ticks = %d\n"
% (DENSITY_PERIOD, DENSITY_MIN_TICKS))
"laser_floor_density = 0\n" + DENSITY_CONF_BASE)
# The shipped density default: no floor key, so the board's floor applies.
DENSITY_CONF_FLOORED = "laser_power_model = density\n" + DENSITY_CONF_BASE
DENSITY_LEVEL = tuple(int(x * PWM_PERIOD / RPM_MAX) for x in LADDER_S)
# A $35 typed ahead of the job: rule 18 says the arm overwrites it.
JOB_DENSITY = ["$35=0"] + JOB_LADDER
def duty_for_floor(s, floor_pct):
"""Duty the core computes for an S word against a given floor."""
lo = int(PWM_PERIOD * floor_pct / 100.0)
return int(s * (PWM_PERIOD - lo) / RPM_MAX) + lo
# Sessions L-N: the M101 dose-model switch. One cut, the spindle off,
# the switch, a second cut at the same S. Each cut is a kernel run of
# its own (the planner drains at WAIT_IDLE), so the switch lands between
# runs, which is the only place it is allowed to.
SWITCH_S = 500
SWITCH_MM = 5.0
SWITCH_FEED = 600
SWITCH_TICKS = SWITCH_MM / (SWITCH_FEED / 60.0) * 28160
def job_switch(mcode):
return [
"G91", "G21",
"M3 S%d" % SWITCH_S,
"G1 X%g F%d" % (SWITCH_MM, SWITCH_FEED),
WAIT_IDLE, ("sleep", 0.5),
"M5",
mcode,
"M3 S%d" % SWITCH_S,
"G1 X%g" % -SWITCH_MM,
WAIT_IDLE, ("sleep", 0.5),
"M5",
]
JOB_SWITCH_A2D = job_switch("M101 P1")
JOB_SWITCH_D2A = job_switch("M101 P0")
# The refusal: the switch arrives with the spindle still on. The stream
# must be what the job without the M101 would have produced.
JOB_SWITCH_REFUSED = [
"G91", "G21",
"M3 S%d" % SWITCH_S,
"G1 X%g F%d" % (SWITCH_MM, SWITCH_FEED),
WAIT_IDLE, ("sleep", 0.5),
("expect_error", "M101 P1"),
"G1 X%g" % -SWITCH_MM,
WAIT_IDLE, ("sleep", 0.5),
"M5",
]
def job_revert(mcode):
"""Two programs: the first switches and ends in M2, the second cuts
at the same S with no switch of its own."""
return [
"G91", "G21",
mcode,
"M3 S%d" % SWITCH_S,
"G1 X%g F%d" % (SWITCH_MM, SWITCH_FEED),
WAIT_IDLE, ("sleep", 0.5),
"M5", "G90", "M2", ("sleep", 1.0),
"G91",
"M3 S%d" % SWITCH_S,
"G1 X%g" % -SWITCH_MM,
WAIT_IDLE, ("sleep", 0.5),
"M5",
]
JOB_SWITCH_REVERT = job_revert("M101 P0")
JOB_SWITCH_STICKY = job_revert("M101 P0 Q1")
# Session H: three levels inside one kernel run. The moves are short and
# fast so the planner never drains, and each carries its own S word, so
# the level changes land mid-run. Analog pays a power byte per level;
@@ -235,14 +333,14 @@ def fail(msg):
sys.exit(1)
def send_line(sock, line, log):
def send_line(sock, line, log, expect_error=False):
sock.sendall((line + "\n").encode())
while True:
r = read_avail(sock, log, 5.0, until=("ok", "error"))
if r is None:
fail("no ok/error for %r" % line)
if r == "error":
fail("error response to %r" % line)
if (r == "error") != expect_error:
fail("%s response to %r" % (r, line))
return
@@ -342,6 +440,11 @@ def run_session(name, steps, conf=None, workdir=None, keep=False,
wait_idle(sock, log)
elif isinstance(step, tuple) and step[0] == "sleep":
time.sleep(step[1])
elif isinstance(step, tuple) and step[0] == "expect_error":
send_line(sock, step[1], log, expect_error=True)
# The core skips every G-code line after an error until
# the sender resyncs with an empty line (or a $ command).
send_line(sock, "", log)
else:
send_line(sock, step, log)
@@ -667,18 +770,14 @@ def main():
[counts[d] for d in LADDER_DUTY], gap_d))
# --- session E: the same ladder under the density model -------------
# $35 is written by a first launch and takes effect on the second:
# the floor exists only to keep an analog duty out of the tube's
# dead band, and under density it would just clamp the light end.
wd = tempfile.mkdtemp(prefix="laser-test-")
run_session("density-setup", ["$35=0"], conf=DENSITY_CONF, workdir=wd,
keep=True, arm_required=False)
dens = run_session("density", JOB_DENSITY, conf=DENSITY_CONF, workdir=wd)
# Unfloored through the config key (laser_floor_density = 0), which
# the arm loads into $35.
dens = run_session("density", JOB_LADDER, conf=DENSITY_CONF)
rendered = check_density("density", dens, DENSITY_LEVEL, DENSITY_PERIOD,
DENSITY_MIN_TICKS)
check_termination("density", dens)
if "laser armed (density)" not in run_session.text:
fail("[density] the arm did not select the density model")
if "laser armed (density, floor 0 %)" not in run_session.text:
fail("[density] the arm did not select the density model at floor 0")
print("PASS [density]: %d bytes, %d power bytes all at full duty, "
"level->density %s"
% (len(dens), sum(1 for b in dens if b & 0x80), rendered))
@@ -689,7 +788,7 @@ def main():
"inside the %d the core commanded" % (d_fire, a_fire))
# --- session F: full level under the model is continuous fire -------
full = run_session("density-full", ["$35=0"] + JOB_M3_TERM, conf=DENSITY_CONF)
full = run_session("density-full", JOB_M3_TERM, conf=DENSITY_CONF)
ticks = tick_bytes(full)
spans = fire_spans(ticks)
if not spans:
@@ -703,7 +802,7 @@ def main():
% (b - a))
# --- session G: churn under the model (rules 7-9 still hold) --------
ch = run_session("density-churn", ["$35=0"] + JOB_CHURN, conf=DENSITY_CONF)
ch = run_session("density-churn", JOB_CHURN, conf=DENSITY_CONF)
if not count_fire(ch):
fail("[density-churn] no FIRE bits in the stream")
check_termination("density-churn", ch)
@@ -779,6 +878,171 @@ def main():
"G1; 2 fire spans of %s ticks"
% (name, [s1 - s0 for s0, s1 in spans]))
# --- rule 18: the floor is derived from the key, never typed --------
# The same ladder with a $35=0 typed ahead of it, under the shipped
# density default (no floor key): the arm loads the board's floor and
# every rung renders through it.
floored = run_session("floor-derived", JOB_DENSITY, conf=DENSITY_CONF_FLOORED)
expect_levels = tuple(duty_for(x) for x in LADDER_S)
check_density("floor-derived", floored, expect_levels, DENSITY_PERIOD,
DENSITY_MIN_TICKS)
if "laser armed (density, floor %g %%)" % PWM_MIN_PCT not in run_session.text:
fail("[floor-derived] the arm report does not name the derived floor "
"(text: %r)" % run_session.text[-400:])
print("PASS [floor-derived]: a typed $35=0 is overwritten at the arm; the "
"ladder renders through the %g %% floor key, levels %s"
% (PWM_MIN_PCT, list(expect_levels)))
# --- sessions L: the switch, both directions (rule 19) --------------
def split_at_switch(data, marker):
"""Byte offset of the first power byte satisfying marker(duty)."""
for i, b in enumerate(data):
if b & 0x80 and marker(b & 0x7F):
return i
return None
def longest_burst(ticks):
run = worst = 0
for t in ticks:
run = run + 1 if t & 0x10 else 0
worst = max(worst, run)
return worst
def fire_by_power(data):
"""Fire ticks per power byte in force: the duties FIRE rode."""
cur, out = None, {}
for b in data:
if b & 0x80:
cur = b & 0x7F
elif b & 0x10:
out[cur] = out.get(cur, 0) + 1
return out
# Analog -> density. Before the switch: analog duties, continuous
# FIRE. After: full duty only, FIRE dithered at the level, bursts no
# longer than the base period.
a2d = run_session("switch-a2d", JOB_SWITCH_A2D, conf=ANALOG_CONF)
text = run_session.text
if "laser power model set for this program (density, floor %g %%)" % PWM_MIN_PCT not in text:
fail("[switch-a2d] the switch was not reported (text: %r)" % text[-400:])
cut = split_at_switch(a2d, lambda d: d == PWM_PERIOD)
if cut is None:
fail("[switch-a2d] no full-duty power byte after the switch: the density "
"model never took over")
before, after = a2d[:cut], a2d[cut:]
duty = duty_for(SWITCH_S)
# A run may lead with a dark duty-0 byte across the idle pads; what
# matters is the duty FIRE rides on each side of the switch.
if set(fire_by_power(before)) != {duty}:
fail("[switch-a2d] FIRE rode duties %s before the switch, expected only %d"
% (sorted(fire_by_power(before)), duty))
if set(b & 0x7F for b in after if b & 0x80) != {PWM_PERIOD}:
fail("[switch-a2d] duties after the switch %s: a level reached PWMSAR "
"under density" % sorted(set(b & 0x7F for b in after if b & 0x80)))
tb, ta = tick_bytes(before), tick_bytes(after)
sb, sa = fire_spans(tb), fire_spans(ta)
if len(sb) != 1 or len(sa) != 1:
fail("[switch-a2d] fire spans before/after the switch %s / %s, expected "
"one each" % (sb, sa))
if longest_burst(ta) > DENSITY_PERIOD:
fail("[switch-a2d] a %d-tick continuous FIRE burst at full duty after the "
"switch: a torn transition" % longest_burst(ta))
dens_after = sum(1 for t in ta[sa[0][0]:sa[0][1]] if t & 0x10) / float(sa[0][1] - sa[0][0])
if abs(dens_after - duty / float(PWM_PERIOD)) > 0.03:
fail("[switch-a2d] density after the switch %.3f, expected %.3f"
% (dens_after, duty / float(PWM_PERIOD)))
check_termination("switch-a2d", a2d)
print("PASS [switch-a2d]: analog duty %d before, full duty + density %.3f after, "
"longest burst %d <= %d" % (duty, dens_after, longest_burst(ta), DENSITY_PERIOD))
# Density -> analog. The analog default floor (16) applies after the
# switch, so the duty is the one that floor gives.
d2a = run_session("switch-d2a", JOB_SWITCH_D2A, conf=DENSITY_CONF_FLOORED)
text = run_session.text
if "laser power model set for this program (analog, floor %g %%)" % ANALOG_FLOOR_DEFAULT_PCT not in text:
fail("[switch-d2a] the switch was not reported with the analog floor (text: %r)"
% text[-400:])
duty_a = duty_for_floor(SWITCH_S, ANALOG_FLOOR_DEFAULT_PCT)
cut = split_at_switch(d2a, lambda d: d == duty_a)
if cut is None:
fail("[switch-d2a] no analog power byte (%d) after the switch" % duty_a)
before, after = d2a[:cut], d2a[cut:]
if set(fire_by_power(before)) != {PWM_PERIOD}:
fail("[switch-d2a] FIRE rode duties %s before the switch, expected full only"
% sorted(fire_by_power(before)))
if set(b & 0x7F for b in before if b & 0x80) - {PWM_PERIOD, 0}:
fail("[switch-d2a] a density level shipped as a duty across the switch: "
"power bytes %s" % sorted(set(b & 0x7F for b in before if b & 0x80)))
if set(fire_by_power(after)) != {duty_a}:
fail("[switch-d2a] FIRE rode duties %s after the switch, expected only %d"
% (sorted(fire_by_power(after)), duty_a))
ta = tick_bytes(after)
sa = fire_spans(ta)
if len(sa) != 1:
fail("[switch-d2a] fire spans after the switch %s, expected one" % sa)
got = sum(1 for t in ta[sa[0][0]:sa[0][1]] if t & 0x10) / float(sa[0][1] - sa[0][0])
if got < 0.999:
fail("[switch-d2a] FIRE after the switch is not continuous (%.3f): the "
"dither is still masking under analog" % got)
check_termination("switch-d2a", d2a)
print("PASS [switch-d2a]: full duty + dither before, continuous FIRE at duty %d "
"(floor %g) after" % (duty_a, ANALOG_FLOOR_DEFAULT_PCT))
# --- session M: refused with the spindle on (rule 20) ---------------
ref = run_session("switch-refused", JOB_SWITCH_REFUSED, conf=ANALOG_CONF)
text = run_session.text
if "M5 first" not in text or "error:253" not in text:
fail("[switch-refused] the refusal was not reported as error 253 with its "
"reason (text: %r)" % text[-400:])
if "laser power model set" in text:
fail("[switch-refused] the switch was applied despite the refusal")
if set(fire_by_power(ref)) != {duty}:
fail("[switch-refused] FIRE rode duties %s, expected only %d: the stream "
"changed under a refused switch" % (sorted(fire_by_power(ref)), duty))
check_cut_spans("switch-refused", tick_bytes(ref), 2, SWITCH_TICKS,
"the two G1 moves, both analog")
check_termination("switch-refused", ref)
print("PASS [switch-refused]: M101 with the spindle on -> error:253, stream "
"unchanged (duty %d throughout)" % duty)
# --- session N: program scope and Q1 (rule 21) ----------------------
rev = run_session("switch-revert", JOB_SWITCH_REVERT, conf=DENSITY_CONF_FLOORED)
text = run_session.text
if "laser power model reverted (density, floor %g %%)" % PWM_MIN_PCT not in text:
fail("[switch-revert] M2 did not report the revert (text: %r)" % text[-600:])
if text.count("laser armed (analog, floor %g %%)" % ANALOG_FLOOR_DEFAULT_PCT) != 1 or \
text.count("laser armed (density, floor %g %%)" % PWM_MIN_PCT) != 1:
fail("[switch-revert] expected one analog arm then one density arm "
"(text: %r)" % text[-600:])
cut = split_at_switch(rev, lambda d: d == PWM_PERIOD)
if cut is None:
fail("[switch-revert] the second job never rendered under density")
before, after = rev[:cut], rev[cut:]
if set(fire_by_power(before)) != {duty_a}:
fail("[switch-revert] first job FIRE rode duties %s, expected the analog %d"
% (sorted(fire_by_power(before)), duty_a))
if longest_burst(tick_bytes(after)) > DENSITY_PERIOD:
fail("[switch-revert] continuous FIRE at full duty in the second job: the "
"revert did not restore the dither")
check_termination("switch-revert", rev)
print("PASS [switch-revert]: job 1 analog at duty %d, M2 reverts, job 2 density"
% duty_a)
stk = run_session("switch-sticky", JOB_SWITCH_STICKY, conf=DENSITY_CONF_FLOORED)
text = run_session.text
if "reverted" in text:
fail("[switch-sticky] a Q1 switch was reverted at M2")
if text.count("laser armed (analog, floor %g %%)" % ANALOG_FLOOR_DEFAULT_PCT) != 2:
fail("[switch-sticky] expected both jobs to arm analog (text: %r)" % text[-600:])
if set(fire_by_power(stk)) != {duty_a}:
fail("[switch-sticky] FIRE rode duties %s, expected the analog %d in both jobs"
% (sorted(fire_by_power(stk)), duty_a))
check_cut_spans("switch-sticky", tick_bytes(stk), 2, SWITCH_TICKS,
"one G1 per job, both analog")
check_termination("switch-sticky", stk)
print("PASS [switch-sticky]: M101 P0 Q1 holds across M2; both jobs analog at "
"duty %d" % duty_a)
print("PASS: all stream emission rules hold")