Pin forgectrl f9b4893: the air-assist ground shift off the coolant readings

The pin carries the compensation (cool_aa_offset_counts, the
aa-offset-calibrate diagnostic, the panel's Apply); verified with
bitbake -c fetch. The catalog gains cooling.aa-offset-calibrate, which
runs the tool and checks its recommendation and spread.

scripts/bench/offset_probe.py is the differential probe that found the
source: one actuator switched at a time with both sensors at 25 Hz
(survey), the air-assist duty ladder, the gantry jogging under the fan,
and an armed dark dwell. CAMPAIGN-LOG records the four probes and the
result; BRINGUP item 21 names the setting and the calibrate as what
remains on this machine, and item 23 opens the initial commissioning
procedure.

No catalog consequence beyond the new case: a bench tool and records.
This commit is contained in:
ScottW514
2026-08-29 17:36:02 -04:00
parent 61b68c387c
commit 8831d9b20e
6 changed files with 626 additions and 8 deletions
+72
View File
@@ -4420,6 +4420,78 @@ head jogged back by the baseline; the case now brings the head back
itself. The case rides the next image; its campaign standing comes with
that image's campaign.
## 2026-08-29: the coolant ADC offset is the air-assist fan's return current
The common-mode offset on the two coolant sensors (about 1 C low while the
run airflow profile is on, BRINGUP item 21) was run down differentially,
dark, with `scripts/bench/offset_probe.py`: forgectrl idle, one actuator
switched at a time, both sensors at 25 Hz, the step at every edge scored
as the 1.5 s means after minus before. Records
`bench-data/offset_probe_20260829-205928.json` (the survey) and
`offset_probe_20260829-210233.json` (the ladder).
The wiring first, from the OpenGlow board's netlist (pin-compatible with
the factory board): the thermistors enter on J2 pins 3 and 4 with the pump
enable (2), the TEC enable (1), the TEC thermistor (6), the heater PWM (7),
the exhaust tach (8) and the exhaust PWM (9) beside them, then 12 V, the
beam-detect lines, Z step and direction, the head I2C and the head camera
lanes; the intake fans, the HV lines, `LASER_ON` and `HV_EN` are on J1;
the air assist is driven on the head. The run profile drives the exhaust
at 65535 (100 %, no PWM edges) and the intakes at 43278.
The survey: exhaust at 100 %, 50 % and 25 %, the intakes at their run
duty, purge, the TEC enable and the lid lamp each move both sensors by
0.1 C or less; the heater and the pump edges move the downstream sensor
only (thermal). The air assist from its idle 204 to its run 1023 steps
both sensors together, -1.37 and -1.25 C in one sample, and back +1.18 and
+1.13; "all run fans" gives the same -1.28 and -1.23. The ladder: 256
-0.03, 512 -0.27, 768 -0.6, 1023 -1.2 C cumulative, both sensors alike,
each step reversed on the way down, and -1.2 to -1.3 C on two full on and
off repeats. The offset is proportional to the air-assist fan's current: a
ground-return drop on a path the thermistor reference shares, not
crosstalk on J2 and not HV (the `flowload` traces already show the step
before any HV and no further step at emission). Both sensors read low by
the same amount whenever the air assist runs, so the flow check's rise is
untouched now that its baseline is taken under the run profile, and the
over-temperature gates read the coolant about 1.2 C cooler than it is
during a job. The mid-run toggling between two levels is not reproduced by
a steady fan (0 toggles in every dwell); the fan's own current variation
under motion is the remaining candidate.
## 2026-08-29: the toggling is not motion
`offset_probe.py jog` (record `bench-data/offset_jog_20260829-211710.json`),
dark, no press: the air assist steady at its run duty while the gantry
jogged 30 mm in X and 8 mm in Y for 40 s, then the same jog with the fan
idle. Zero level toggles in every phase; with the fan on the readings sat
1.1 C low and as quiet while jogging (sd 0.26 C) as while still (0.32),
and the fan's tach held 677 to 678 under motion. Motion and the head's
pogo contacts under vibration are out. The toggling seen in the day's
`flowload t2` traces sits inside the armed windows only (from the moment
`armed` went true, past the burst's end, gone when the fans went idle), and
the dark runs with the fans at run duty show none, which leaves the HV
supply's enable, asserted from the press to the disarm, as the candidate;
an armed dark dwell (`M3 S0`, the window open, no emission) is the test.
## 2026-08-29: the toggling needs the tube lit
`offset_probe.py armed` (record `bench-data/offset_armed_20260829-212245.json`):
`M3 S0`, the press 0.3 s after the M3, the window open 73 s with the head
still, the flow check's heater running inside it, no emission (0 lit
samples on the LASER_ON witness and the tube current), then M2. Zero level
toggles on both sensors through the armed window; the one step after M2
is the fans returning to idle. The `hv_enable` switch read false
throughout, so it does not follow the arm. Every toggle in the day's
`flowload t2` traces sits inside a lit period (seven between +7 and +34 s
around a burst lit from +7 to +27; thirteen under a 41 s burst;
twenty-two under a 48 s burst), and none appear dark, with the fans
alone, under motion, or in an armed dark window. The jitter comes with
tube current: the HV supply's input current on a return the thermistor
reference shares, or its switching, is what remains, and a scope on the
two sensor lines during a cut is the next instrument. Its size is 0.6 to
1.1 C either way, inside the over-temperature ceiling's 2 C hysteresis,
and the flow check reads means.
## Superseded status notes
### Shared machine services — remaining polish, as listed 2026-08-13