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Add cooling.flow-under-load: the flow check with the tube lit through its window
A live catalog case: two 30 x 4 mm fills at full power on the press, the window held open until the engine's flow verdict lands in the forgectrl log, then M2 and the head brought back. PASS needs a verified line with the laser's share on it (at least 0.3 C: the window and the fire overlapped) and the judged rise at least 1 C under cool_flow_rise; an arm refused by a gate names the gate. Passed on image 20260829190323 (heater rise 11.9 C judged, laser 0.6 off 12.5). CAMPAIGN-LOG records the run and the day's two air-assist gate holds (a bench connection, reseated); BRINGUP item 21 names the case. Catalog: the case covers forgectrl src/cool.* and its neighbors; a new test, so the manifest's coverage widens rather than moves.
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ScottW514
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@@ -1463,11 +1463,11 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`.
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and toggles between two levels in between. Together they put an
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ordinary job's check within a few tenths of the limit. The engine now
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reads means and takes the tube's share off (`cool_laser_heat_cw`,
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`cool_laser_heat_density`). Owed: a `cooling.*` catalog case with an
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armed CW load; a re-measure of the two coefficients once a second
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machine is on the bench (one tube, one supply so far); and if a lit
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check still trips, the void-on-emission design with the tube as its
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own flow tracer.
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`cool_laser_heat_density`), and `cooling.flow-under-load` is the
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catalog's case. Owed: a re-measure of the two coefficients once a
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second machine is on the bench (one tube, one supply so far); and if a
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lit check still trips, the void-on-emission design with the tube as
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its own flow tracer.
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Open question, the offset's source: the timing points at the airflow
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drive (the step lands one sample after the fans go to run duty, before
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any HV, and lifts when they go idle, long after the tube is dark), but
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@@ -4388,6 +4388,38 @@ and the reset came twice, 0.1 s apart: the tail of the blast arrived after
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the first reset had flushed the ring and overran it again. Harmless, the
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job was already stopped.
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## 2026-08-29: the air-assist fan and the airflow gate, twice
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Twice in the day the airflow gate held a job at the end of its 15 s grace
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with the air-assist tach still at its idle reading (1895 at 17:09 in a
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`flowload t2 40` run, 2207 at 20:19 in the first bench run of
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`cooling.flow-under-load`; the floor is 6000 and every other session of the
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day read about 10,700 within 5 s of the run profile). The head probed clean
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and the kernel log carried no I2C error; the fan read normal at idle both
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times. The gate did what it is for: the hold came before the arm, the
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operator's press was refused, the session closed with the fans, and no job
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ran without air. The operator's reading is a bench hardware glitch, the
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head's pogo-pin connection to the air assist; the machine was powered down
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and the head reseated, and the case was run again. Not a project item.
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## 2026-08-29: `cooling.flow-under-load`, the catalog's case for the lit check
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The catalog case for BRINGUP item 21 (`forgetest/suite/cooling.py`, kind
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live, mode grbl, one press): two 30 x 4 mm fills at full power on the press,
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the window held open until the engine's verdict lands in the forgectrl log,
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then M2. PASS needs `coolant flow verified` with the laser's share on the
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line (at least 0.3 C, the proof the window and the fire overlapped) and the
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judged rise at least 1 C under `cool_flow_rise`; an arm refused by a gate
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names the gate. First run on image 20260829190323 (the module staged over
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the installed suite, forgetest restarted; the prerequisites overridden, no
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campaign results on this image yet): the airflow gate held before the arm
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(the entry above). Second run after the head reseat: **PASS**, the engine
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line `coolant flow verified (heater rise 11.9 C, dT 9.5 C; laser 0.6 off
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12.5)`, 66 s from job to verdict, the window closed 0.0 s after M2, the
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head jogged back by the baseline; the case now brings the head back
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itself. The case rides the next image; its campaign standing comes with
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that image's campaign.
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## Superseded status notes
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### Shared machine services — remaining polish, as listed 2026-08-13
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@@ -622,3 +622,137 @@ def fan_gate_trips(ctx):
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ctx.check(all(after.get(k, "") == orig[k] for k in FAN_KEYS),
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"settings not restored: %s", {k: after.get(k) for k in FAN_KEYS})
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ctx.check(fc.wait_idle(60, abort=ctx.aborted), "machine did not return to idle")
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# The flow check under a lit tube. With a prompt press the tube is lit for
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# most of the arm-time window, which adds about 1.5 C to the heater rise at
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# full power; the engine takes that share off from the tube current before
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# the limit (cool_laser_heat_*), reads its baseline and end as means, and
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# says so on the verdict line: "verified (heater rise 11.3 C, dT 9.6 C;
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# laser 0.8 off 12.0)". The share on the line is the proof the window and
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# the fire overlapped; the judged rise inside the dark band is the proof
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# the share was right.
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LOAD_FEED = 1500 # mm/min: 25 mm/s, the engrave dose that does not char
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LOAD_PITCH = 0.3 # mm between lines
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LOAD_WIDTH = 30.0 # mm, the line length (+X)
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LOAD_LINES = 27 # two 30 x 4 mm fills back to back, about 35 s lit
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LOAD_SHARE_MIN_C = 0.3 # the tube was lit inside the window
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LOAD_MARGIN_C = 1.0 # the judged rise this far under the limit
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LOAD_VERDICT_WAIT_S = 120 # the window opens ~15 s into the session and runs 50 s
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LOAD_LOG_LINES = "300"
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_LOAD_LINE_RX = None
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def _load_verdict_rx():
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global _LOAD_LINE_RX
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if _LOAD_LINE_RX is None:
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import re
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_LOAD_LINE_RX = re.compile(
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r"(COOLANT FLOW SUSPECT|COOLANT FLOW FAULT|coolant flow verified|"
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r"coolant flow suspicion cleared|coolant flow recovered)[^\n]*?heater rise ([0-9.]+) C"
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r"(?: \(limit ([0-9.]+))?, dT ([0-9.]+)(?: C)?(?:; laser ([0-9.]+) off ([0-9.]+))?\)?")
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return _LOAD_LINE_RX
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def _load_fill():
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lines = []
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for i in range(LOAD_LINES):
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lines.append("G1 X%g F%d" % (LOAD_WIDTH if i % 2 == 0 else -LOAD_WIDTH, LOAD_FEED))
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if i < LOAD_LINES - 1:
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lines.append("G1 Y%g F%d" % (LOAD_PITCH, LOAD_FEED))
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return lines
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def _forgectrl_tail(fc):
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st, body = fc.get("/logs/tail", params={"name": "forgectrl", "lines": LOAD_LOG_LINES})
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return body.get("text", "") if st == 200 and isinstance(body, dict) else ""
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@test("cooling.flow-under-load", title="The flow check reads true with the tube lit through its window",
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subsystem="cooling", kind="live", mode="grbl", est_min=4,
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covers=_COOL_COVERS + [("forgectrl", "src/main.c")],
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requires=["laser.emission-witness", "cooling.flow-verify"], actions=["button"],
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steps=["Scrap under the head with 35 mm of free +X and 10 mm of +Y travel; lid closed; exhaust on.",
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"Press the physical button AS SOON AS it lights white: the check must run while the "
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"tube is lit, and the share on the verdict line is the proof it did."],
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description="Two 30 x 4 mm fills at full power on the press (about 35 s lit), the window "
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"held open until the engine's flow verdict lands. The verdict must be "
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"'verified' with the laser's share on the line (at least 0.3 C: the tube was "
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"lit inside the window) and the judged rise at least 1 C under the limit, "
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"where the same check read within tenths of the limit before the engine took "
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"the tube's share off and read its baseline as a mean.")
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def flow_under_load(ctx):
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from .laser import sample, prepare, LiveJob, ARM_CUE, run_and_sample, wait_disarm
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fc = ctx.forgectrl
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ev = ctx.evidence
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state, check_s = _gate_state(fc, "cool_flow_check_s")
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_st, limit = _gate_state(fc, "cool_flow_rise")
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ctx.check(state != "off" and check_s, "the flow check is off (cool_flow_check_s=%s)", check_s)
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ctx.check(limit, "cool_flow_rise unreadable")
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ev.update({"check_s": check_s, "limit_c": limit})
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before = _forgectrl_tail(fc).count("heater rise")
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# The fill ends one line length out and (LOAD_LINES - 1) pitches up;
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# the job brings the head back so the baseline finds it where it began.
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back = "G0 X%g Y%g" % (-LOAD_WIDTH if LOAD_LINES % 2 else 0.0, -LOAD_PITCH * (LOAD_LINES - 1))
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job = ["G91", "G21", "M3 S1000"] + _load_fill() + ["M5", back]
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line = None
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heater_seen = False
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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 % "35 mm +X and 10 mm +Y")
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ctx.arm_press()
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t_job = time.time()
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try:
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samples = run_and_sample(ctx, g, job, overall_timeout=240)
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finally:
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ctx.clear_notice()
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emis = [s["emission"] for s in samples if s["emission"] is not None]
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ev["emission_peak"] = max(emis) if emis else 0
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# An arm refused by a gate names itself: the engine's verdict left OK
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# during the wait (AIRFLOW, OVERTEMP, a flow FAULT).
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gates = sorted({s["verdict"] for s in samples if s.get("verdict") not in (None, "OK")})
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ev["verdicts_seen"] = gates
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ctx.check(ev["emission_peak"] > 0,
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"no emission witnessed: %s" % ("the engine held the run (%s) before the arm"
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% ", ".join(gates) if gates
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else "arm refused, or no button press"))
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# The window stays open (no M2) until the check has judged.
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t0 = time.time()
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while time.time() - t0 < LOAD_VERDICT_WAIT_S:
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ctx.checkpoint()
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if hw.sysfs_int("thermal/heater_pwm", 0) > 0:
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heater_seen = True
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text = _forgectrl_tail(fc)
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if text.count("heater rise") > before:
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m = None
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for m in _load_verdict_rx().finditer(text):
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pass
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line = m.group(0) if m else None
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break
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ctx.sleep(1)
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ev["heater_seen"] = heater_seen
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ctx.log("M2: %s", g.command("G90\nM2", timeout=10))
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dt = wait_disarm(ctx, 30)
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ev["disarm_after_m2_s"] = round(dt, 1) if dt is not None else None
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ctx.check(line, "the engine published no flow verdict within %d s of the job (heater seen: %s)",
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LOAD_VERDICT_WAIT_S, heater_seen)
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m = _load_verdict_rx().search(line)
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kind, rise, _lim, dtc, share, raw = m.groups()
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rise = float(rise)
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share = float(share) if share else 0.0
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raw = float(raw) if raw else rise
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ev.update({"verdict_line": line, "kind": kind, "rise_c": rise, "dt_c": float(dtc),
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"laser_share_c": share, "raw_rise_c": raw, "job_to_verdict_s": round(time.time() - t_job, 1)})
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ctx.log("engine: %s", line)
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ctx.check(kind == "coolant flow verified", "the check did not verify flow under load: %s", line)
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ctx.check(share >= LOAD_SHARE_MIN_C,
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"the tube's share on the line is %.1f C (under %.1f): the window and the fire did not "
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"overlap - press the button as soon as it lights", share, LOAD_SHARE_MIN_C)
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ctx.check(rise <= float(limit) - LOAD_MARGIN_C,
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"judged rise %.1f C is within %.1f C of the %.1f C limit", rise, LOAD_MARGIN_C, float(limit))
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ctx.check(dt is not None, "the window did not close after M2")
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ctx.log("PASS: lit through the window, raw rise %.1f C, laser %.1f C off, judged %.1f C against %.1f "
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"(dT %.1f), window closed %.1f s after M2", raw, share, rise, float(limit), float(dtc), dt)
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