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https://github.com/openglow-org/forgefirm.git
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forgetest: the emission witness samples a rapid after its M5; m5-rapid-dark leaves
The rule that a rapid after an M5 ships no FIRE is the host's (laser stream rule 16). What only the machine shows is LASER_ON staying off with FIRE clear while the chain can fire; kernel.fire-line's dark sample runs with the chain unarmed. laser.m5-rapid-dark held that sample in a test of its own, with its own arm and press. The emission witness, which every campaign runs, now holds it. - The square ends at M5 with no program end, so the window stays open. - The dark point: the LASER_ON count reads 0 after the M5, the window still armed, and the SoC lock line released (laser_locked false: the engine's armed flag can read true after the latch has locked, and a dark reading with the latch locked is the unarmed case). All three are checked before anything else is sent. - Only then is the rapid sent: G0 X20, a 2.5 s dwell, G0 X-20, a 0.5 s dwell, the program end. Sending it after the dark point keeps the mid-square dwell's own zero from being taken for the dark point. - The test samples until the window closes (a dwell reports Idle, so Idle cannot end it), with the controller's machine X beside each sample. - Every sample from the dark point until the window closes reads no emission, and the HV current stays at its idle reading (HV_DARK_MAX); the reports show the head out at +20 mm and back at the start inside that stretch, and the latch reads released on the sample at +20 mm. - The square still has to show emission and an HV rise, judged on the samples before the M5; the beam detector is judged there too. - The job-based disarm is timed from the head being back: under 10 s, where the idle grace is 60 s. - The rapid's list and its sampler live inside the test, and the deletion takes only m5-rapid-dark's own lines (decorator through body), so laser.py's shared text is byte-for-byte unchanged. - live_fire_drills.py's m5dark note and the bench README say the emission witness now carries the drill's check. Proof: the fingerprint parts of laser.py before and after: the shared text unchanged, every other test's own text unchanged. In the controller, glowforge_laser.c keeps the latch unlocked from the job's first laser-on through M5/M3 toggles and relocks it at program end or after the laser_disarm_s spindle-off grace (60 s by default), so the dark point and the rapid fall inside the window. The coverage lint reports 0 uncovered paths over 110 tests (its one failure is setup.check-lens's src/lensfind.* entry, which the forgectrl pin bump clears); pyflakes adds no finding; the forgetest host suite passes under Linux. Acceptance: only laser.emission-witness moves, and as an always-required test it must pass on the bench in the next campaign before a release can inherit its PASS.
This commit is contained in:
ScottW514
+109
-101
@@ -457,15 +457,45 @@ def power_floor(ctx):
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"(G4) between its second and third sides: emission_samples (the kernel's "
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"LASER_ON sample count) goes nonzero during the fire window and returns to 0 "
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"at Idle, HV current rises during the burn, the head's beam detector sees the "
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"beam, the armed window is observed, the M2 program end disarms promptly at "
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"Idle (job-based, not the 60 s idle grace) and the button goes dark. Across "
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"the dwell the kernel run ends and restarts: HV_ENABLE drops with the "
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"charge-pump watchdog and is back for the third side, while the hardware "
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"button latch stays clear (cnc/button_latch 0 in every armed sample), so the "
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"second half of the square marks without a second press. The operator "
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"confirms all four sides.")
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"beam, and the armed window is observed. Across the dwell the kernel run ends "
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"and restarts: HV_ENABLE drops with the charge-pump watchdog and is back for "
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"the third side, while the hardware button latch stays clear (cnc/button_latch "
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"0 in every armed sample), so the second half of the square marks without a "
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"second press. The square ends at M5 with the window still open; once the "
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"LASER_ON count reads 0 (the dark point), a rapid runs 20 mm out over the "
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"first side and back, then the program ends. From the dark point until the "
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"window closes, every sample reads no emission and the HV current at its idle "
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"reading, and the head's reports place the rapid inside that stretch: LASER_ON "
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"stays off with FIRE clear while the chain can fire. The M2 program end "
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"disarms promptly (job-based, not the 60 s idle grace) and the button goes "
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"dark. The operator confirms all four sides.")
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def emission_witness(ctx):
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ev = ctx.evidence
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# The rapid after the M5 (G91 is modal from the square): out over the
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# first side and back, then the program end.
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rapid_tail = ["G0 X20", "G4 P2.5", "G0 X-20", "G4 P0.5", "G90", "M2"]
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def sample_to_disarm(g, timeout=20.0, sample_hz=8):
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"""Sample until the armed window closes, or the timeout, with the
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controller's state and machine X beside each sample ("x"). A G4
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dwell reports Idle, so Idle cannot end this; the window closing at
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the program end does."""
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samples = []
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period = 1.0 / sample_hz
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t0 = time.time()
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while time.time() - t0 < timeout:
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ctx.checkpoint()
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smp = sample(ctx)
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rep = g.status_report()
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if smp:
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smp["gstate"] = rep.get("state")
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smp["x"] = (rep.get("MPos") or (None,))[0]
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samples.append(smp)
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if not smp["armed"]:
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break
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time.sleep(period)
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return samples
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with ctx.grbl() as g, LiveJob(ctx, g):
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prepare(ctx, g)
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base = sample(ctx)
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@@ -475,21 +505,46 @@ def emission_witness(ctx):
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base["armed"], base["verdict"])
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ctx.check(not base["emission"], "emission_samples nonzero before the job (%s)", base["emission"])
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ctx.ready(ARM_CUE % "20 mm +X and +Y")
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# The square ends at M5 with no program end: the window stays open
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# for the rapid that follows.
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job = ["G91", "G21", "M4", "S400",
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"G1 X20 F600", "G1 Y20 F600", "G4 P2", "G1 X-20 F600", "G1 Y-20 F600",
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"M5", "G90", "M2"]
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"M5"]
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ctx.arm_press()
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try:
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samples = run_and_sample(ctx, g, job)
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cut = run_and_sample(ctx, g, job)
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# The dark point: the M5 has run, the LASER_ON count reads 0, and
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# the window is still open. The rapid is sent only after it, so
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# the dark stretch covers the rapid by construction, and the
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# mid-square dwell's own zero cannot be taken for it.
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ctx.wait_for(lambda: (sample(ctx) or {}).get("emission") == 0, 10, poll=0.125)
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dark = sample(ctx)
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ctx.check(dark and dark["emission"] == 0,
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"the LASER_ON count did not return to 0 after the M5 (%s)", dark and dark["emission"])
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ctx.check(dark["armed"], "the armed window closed after the M5, before the rapid "
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"(phase %s): the rapid would not run under it", dark["phase"])
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# The engine's armed flag can still read true after the latch has
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# locked, and a dark reading with the latch locked is the unarmed
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# case this sample is here to exclude: the SoC lock line must read
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# released.
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ctx.check(dark["locked"] is False, "the laser latch is locked at the dark point "
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"(laser_locked %s): the rapid would run unarmed", dark["locked"])
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rep = g.status_report()
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dark["gstate"] = rep.get("state")
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dark["x"] = (rep.get("MPos") or (None,))[0]
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ctx.check(dark["x"] is not None, "the controller reports no machine position: %s", rep)
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stream(g, rapid_tail)
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tail = sample_to_disarm(g)
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finally:
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ctx.clear_notice()
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samples = cut + [dark] + tail
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ev["trail_fields"] = list(TRAIL_FIELDS)
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ev["trail"] = trail(samples)
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beam = beam_witness(ctx, ev, samples, base)
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emis = [s["emission"] for s in samples if s["emission"] is not None]
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beam = beam_witness(ctx, ev, cut, base)
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emis = [s["emission"] for s in cut if s["emission"] is not None]
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peak = max(emis) if emis else 0
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end = emis[-1] if emis else None
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hv = [s["hv"] for s in samples if s["hv"] is not None]
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end = next((s["emission"] for s in reversed(samples) if s["emission"] is not None), None)
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hv = [s["hv"] for s in cut if s["hv"] is not None]
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ir_peak = [0, 0, 0, 0]
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for s in samples:
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if s["ir"] and len(s["ir"]) == 4:
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@@ -533,12 +588,34 @@ def emission_witness(ctx):
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ev["exhaust_floor"] = floor
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ctx.log("exhaust at the first emission sample: %s rpm (floor %.0f)",
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ev["exhaust_at_first_fire"], floor)
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# X-3: job-based disarm at Idle after M2
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dt = wait_disarm(ctx, 75)
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ev["disarm_after_idle_s"] = round(dt, 1) if dt is not None else None
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ctx.log("time-to-disarm after Idle: %s s", ev["disarm_after_idle_s"])
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# The rapid after the M5, with the window open and FIRE clear: every
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# sample from the dark point until the window closes reads no emission
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# and the HV current at its idle reading. The head's reports place the
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# rapid inside that stretch: out to +20 mm, then back at the start.
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stretch = [dark] + tail
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x0 = dark["x"]
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i_out = next((i for i, s in enumerate(stretch) if s.get("x") is not None and s["x"] - x0 >= 19.5), None)
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i_back = (next((i for i in range(i_out + 1, len(stretch))
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if stretch[i].get("x") is not None and abs(stretch[i]["x"] - x0) < 0.05), None)
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if i_out is not None else None)
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closed = stretch[-1] if not stretch[-1]["armed"] else None
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relit = [s for s in stretch if s["emission"]]
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hv_dark = max((s["hv"] for s in stretch if s["hv"] is not None), default=0)
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dt = (closed["t"] - stretch[i_back]["t"]) if (closed and i_back is not None) else None
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ev["rapid"] = {"samples": len(stretch), "span_s": round(stretch[-1]["t"] - dark["t"], 2),
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"x_start": x0, "x_max": max((s["x"] for s in stretch if s.get("x") is not None), default=None),
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"out_at_s": round(stretch[i_out]["t"] - dark["t"], 2) if i_out is not None else None,
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"back_at_s": round(stretch[i_back]["t"] - dark["t"], 2) if i_back is not None else None,
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"relit": [(round(s["t"] - dark["t"], 2), s["emission"]) for s in relit][:8],
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"hv_max": hv_dark, "locked_at_dark": dark["locked"],
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"locked_at_out": stretch[i_out]["locked"] if i_out is not None else None}
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ev["disarm_after_idle_s"] = round(dt, 1) if dt is not None else None
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ctx.log("the rapid after the M5: %d samples over %.1f s from the dark point, out at +%s s, back at +%s s, "
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"%d with emission, HV max %s; the window closed %s s after the head was back", len(stretch),
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ev["rapid"]["span_s"], ev["rapid"]["out_at_s"], ev["rapid"]["back_at_s"], len(relit), hv_dark,
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ev["disarm_after_idle_s"])
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ctx.check(armed_seen, "the armed window was never observed (arm refused, or no button press)")
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ctx.check(peak > 0, "no emission witnessed (emission_samples stayed 0)")
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ctx.check(peak > 0, "no emission witnessed on the square (emission_samples stayed 0)")
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first_idle_fire = ev["idle_airflow_fire"][0] if idle_fire else (None, None, None)
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ctx.check(not idle_fire,
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"the laser fired while the cooling engine had no run session, so the fans were at "
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@@ -550,8 +627,18 @@ def emission_witness(ctx):
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"emission sample, floor %.0f)", ev["exhaust_at_first_fire"], floor)
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ctx.check(hv and max(hv) > min(hv), "HV current did not rise during the burn (%s..%s)",
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ev["hv_min"], ev["hv_max"])
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ctx.check(i_out is not None and i_back is not None,
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"the rapid did not run inside the dark stretch: out at %s, back at %s (X from %s, max %s)",
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ev["rapid"]["out_at_s"], ev["rapid"]["back_at_s"], x0, ev["rapid"]["x_max"])
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ctx.check(stretch[i_out]["locked"] is False, "the laser latch was locked with the head at +20 mm "
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"(laser_locked %s): the rapid ran unarmed", stretch[i_out]["locked"])
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ctx.check(not relit, "the laser emitted after the M5: %d samples, first at +%s s (emission_samples %s) "
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"- a rapid after M5 fired", len(relit), relit[0]["t"] - dark["t"] if relit else None,
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relit[0]["emission"] if relit else None)
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ctx.check(hv_dark <= HV_DARK_MAX, "HV current %s after the M5 (idle reads ~0): the discharge ran "
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"through the rapid", hv_dark)
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ctx.check(dt is not None and dt < 10.0,
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"the M2 job did not disarm promptly at Idle (%s s; the idle grace is ~60 s)",
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"the M2 job did not disarm promptly (%s s after the head was back; the idle grace is ~60 s)",
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ev["disarm_after_idle_s"])
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ctx.check(gap["button_latch_unlocked_samples"] and gap["button_latch_unlocked_max"] == 0,
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"the hardware button latch read SET while the laser latch was unlocked (max %s over %d "
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@@ -563,93 +650,14 @@ def emission_witness(ctx):
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judge_beam(ctx, beam)
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check_button_dark(ctx, ev)
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ctx.confirm("Did the laser mark a 20 mm square outline on the scrap, all four sides?")
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ctx.log("PASS: emission peak %s -> 0, HV %s..%s, beam +%s, disarmed %.1f s after Idle, button "
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"dark, mark confirmed", peak, ev["hv_min"], ev["hv_max"], beam["delta"], dt)
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ctx.log("PASS: emission peak %s -> 0, HV %s..%s, beam +%s; the rapid after the M5 dark (HV max %s); "
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"disarmed %.1f s after the head was back, button dark, mark confirmed", peak, ev["hv_min"],
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ev["hv_max"], beam["delta"], hv_dark, dt)
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HV_DARK_MAX = 20 # hv_current_raw reads 0 with the tube off; hundreds under fire
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@test("laser.m5-rapid-dark", title="The rapids after an M5 ship dark",
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subsystem="laser", kind="live", mode="grbl", est_min=3,
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covers=_LASER_COVERS,
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requires=["laser.emission-witness"], actions=["button"],
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steps=["Scrap under the head with 20 mm of free +X travel; lid closed; exhaust on.",
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"Press the physical button when it lights white (the arm)."],
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description="A 20 mm line at constant power (M3 S400/F600), then M5, a dwell, a rapid back "
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"over the line, a dwell, a rapid forward, a dwell, and the program end. M5 "
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"executes with the planner drained and the kernel run over, and the core "
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"issues no per-segment laser update for moves made with the spindle off, so "
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"only the stream's own wanted state decides whether those rapids fire; a stale "
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"true there lights them at the last level, full duty under the density model. "
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"The kernel's LASER_ON sample count must go to 0 after the M5 and stay 0 "
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"through both rapids, and the HV current must stay at its idle reading.")
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def m5_rapid_dark(ctx):
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ev = ctx.evidence
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with ctx.grbl() as g, LiveJob(ctx, g):
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prepare(ctx, g)
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base = sample(ctx)
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ctx.check(base, "forgectrl /status or /cool/status unavailable")
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ctx.check(not base["emission"], "emission_samples nonzero before the job (%s)", base["emission"])
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ctx.ready(ARM_CUE % "20 mm +X")
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# +20 out on the cut, then the two rapids the test is about, then
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# a third that puts the head back where the job found it: the
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# first two net to +20 and a job that walks the head 20 mm and
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# leaves it there is dirt the hand-back has to jog out. The
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# return is inside the sampling window and after the M5, so it is
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# one more rapid that must be dark, which is what the test asks
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# of the other two.
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job = ["G91", "G21", "M3", "S400",
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"G1 X20 F600",
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"M5", "G4 P2.5",
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"G0 X-20", "G4 P2.5",
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"G0 X20", "G4 P2.5",
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"G0 X-20", "G4 P0.5",
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"G90", "M2"]
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ctx.arm_press()
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try:
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samples = run_and_sample(ctx, g, job)
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# The controller reports Idle inside a G4 dwell, so the sampler
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# above can return before the rapids; the window closing at M2
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# is the end of the job. Keep sampling until then.
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t0 = time.time()
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while time.time() - t0 < 30:
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ctx.checkpoint()
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smp = sample(ctx)
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if smp:
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samples.append(smp)
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if not smp["armed"]:
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break
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time.sleep(0.125)
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finally:
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ctx.clear_notice()
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emis = [(s["t"], s["emission"], s["hv"]) for s in samples if s["emission"] is not None]
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peak = max((e for _t, e, _hv in emis), default=0)
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ctx.check(peak > 0, "no emission witnessed on the G1 (emission_samples stayed 0)")
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# The first zero after the peak is the dark window the M5 and its dwell
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# produce; everything after it is the two rapids and their dwells.
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i_peak = max(range(len(emis)), key=lambda i: emis[i][1])
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after = [x for x in emis[i_peak:] if x[1] == 0]
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ctx.check(after, "emission_samples never returned to 0 after the M5")
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t_dark = after[0][0]
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tail = [x for x in emis if x[0] >= t_dark]
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relit = [x for x in tail if x[1]]
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hv_tail = max((hv for _t, _e, hv in tail if hv is not None), default=0)
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ev.update({"samples": len(samples), "emission_peak": peak, "tail_samples": len(tail),
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"relit_samples": len(relit), "hv_tail_max": hv_tail,
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"relit_first": relit[0] if relit else None})
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ctx.log("emission peak %s; dark from +%.1f s; %d samples after it spanning %.1f s, %d with "
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"emission, HV max after dark %s", peak, t_dark - emis[0][0], len(tail),
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tail[-1][0] - t_dark, len(relit), hv_tail)
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ctx.check(tail[-1][0] - t_dark >= 5.0, "sampling ended %.1f s after the dark point, before "
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"both rapids and their dwells (~5.2 s) had run", tail[-1][0] - t_dark)
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ctx.check(not relit, "the laser emitted after the M5: %d samples, first at +%.1f s "
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"(emission_samples %s) - a rapid after M5 fired at the last level",
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len(relit), (relit[0][0] - t_dark) if relit else 0, relit[0][1] if relit else None)
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ctx.check(hv_tail <= HV_DARK_MAX, "HV current %s after the M5 (idle reads ~0): the discharge "
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"ran through a rapid", hv_tail)
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ctx.log("PASS: emission peak %s on the G1, 0 through both rapids, HV %s after the M5",
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peak, hv_tail)
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@test("laser.armed-kill", title="Armed kill mid-fire: the expected stop, then a SIGKILL",
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