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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
@@ -0,0 +1,466 @@
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#!/usr/bin/env python3
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"""Coolant-sensor offset probe: which actuator moves both thermistors?
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The coolant ADC reads about 1 C low on both sensors while the run airflow
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profile is on, stepping in one sample after the fans start, out when they
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stop, and toggling between two levels in between. The two thermistor
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lines ride J2 pins 3 and 4 beside the pump enable (2), the TEC enable (1),
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the heater PWM (7), the exhaust tach (8) and the exhaust PWM (9); the
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intake fans and the HV lines are on J1, the air assist on the head. This
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probe switches one actuator at a time, dark (no laser, no press), with
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both sensors sampled at 25 Hz, and scores the common-mode step at every
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edge and the toggling inside every dwell. Runs on the board with
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forgectrl idle (the engine writes the fans only at session transitions,
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so a write here stands until the next session); every value is restored
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on the way out, whatever happens. The pump is stopped for one short dwell
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with the tube dark and the heater off, the one pump-off state allowed.
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Usage: offset_probe.py [repeat] (repeats of the exhaust-run edge, default 2)
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offset_probe.py ladder (the air-assist duty ladder alone: the step
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against duty tells a current-proportional
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ground drop from a threshold)
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offset_probe.py jog (the air assist steady at its run duty while
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the gantry jogs, dark: do the readings toggle
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under motion? controller idle in GRBL mode,
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35 mm +X and 10 mm +Y free; no laser, no press)
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Record: FORGETEST_BENCH_DATA or /tmp, offset_probe_<stamp>.json (jog: offset_jog_<stamp>.json)
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"""
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import json
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import math
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import os
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import sys
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import threading
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import time
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SYSFS = '/sys/glowforge/'
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LEDS = '/sys/class/leds/'
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HZ = 25
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PRE, POST, GAP = 1.5, 1.5, 0.3 # seconds around an edge for the step means
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# B-equation from status.c: 10k B3380 NTC in a 10k divider behind a 1.3x
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# reference.
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ADC_F = 1024.0 * 1.3
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RINF = 10000.0 * math.exp(-3380.0 / 298.15)
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def degc(raw):
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if raw is None or raw <= 0 or raw >= ADC_F:
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return float('nan')
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r = 10000.0 / (ADC_F / raw - 1.0)
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return 3380.0 / math.log(r / RINF) - 273.15
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def rd(path):
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try:
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with open(path) as f:
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return f.read().strip()
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except OSError:
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return None
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def wr(path, val):
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with open(path, 'w') as f:
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f.write(str(val))
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class Sampler(threading.Thread):
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def __init__(self):
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super().__init__(daemon=True)
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self.samples = []
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self.stop = threading.Event()
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def run(self):
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period = 1.0 / HZ
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nxt = time.time()
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while not self.stop.is_set():
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t = time.time()
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a, b = rd(SYSFS + 'pic/water_temp_1'), rd(SYSFS + 'pic/water_temp_2')
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self.samples.append((t, int(a) if a and a.isdigit() else None,
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int(b) if b and b.isdigit() else None))
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nxt += period
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d = nxt - time.time()
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if d > 0:
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time.sleep(d)
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else:
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nxt = time.time()
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def mean_c(samples, t0, t1, idx):
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v = [degc(s[idx]) for s in samples if t0 <= s[0] < t1 and s[idx] is not None]
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v = [x for x in v if x == x]
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return sum(v) / len(v) if v else None
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def toggles(samples, t0, t1):
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"""Level steps inside a dwell: both sensors' half-second means moving
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0.45 C or more the same way, agreeing within 0.4 C (the flowload
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detector)."""
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pts = [(s[0], degc(s[1]), degc(s[2])) for s in samples
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if t0 <= s[0] < t1 and s[1] is not None and s[2] is not None]
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pts = [p for p in pts if p[1] == p[1] and p[2] == p[2]]
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w, gap, n = 12, 2, 0
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i = w + gap
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while i < len(pts) - w - gap:
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pre = pts[i - gap - w:i - gap]
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post = pts[i + gap:i + gap + w]
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dd = sum(p[1] for p in post) / w - sum(p[1] for p in pre) / w
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du = sum(p[2] for p in post) / w - sum(p[2] for p in pre) / w
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if abs(dd) >= 0.45 and abs(du) >= 0.45 and (dd > 0) == (du > 0) and abs(dd - du) <= 0.4:
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n += 1
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i += w + 2 * gap
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else:
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i += 1
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return n
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def run_jog():
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"""The air assist steady at its run duty while the gantry jogs, dark:
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does motion make the readings toggle between two levels? Phases: still
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/ fan on still / fan on jogging / fan on still / fan off jogging / fan
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off still. Needs the controller idle in GRBL mode and 35 mm of free +X
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and 10 mm of +Y travel; no laser, no press. The Grbl client comes from
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live_fire_drills (the bench directory on PYTHONPATH)."""
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from live_fire_drills import Grbl, HOST, PORT
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aa = SYSFS + 'head/air_assist_pwm'
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orig = rd(aa)
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g = Grbl(HOST, PORT)
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st = g.status()
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if 'Idle' not in st:
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print('REFUSED: controller is %s, expected Idle' % st)
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return 2
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print('G91/G21: %s / %s' % (g.cmd('G91'), g.cmd('G21')))
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sampler = Sampler()
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sampler.start()
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tach = []
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phases = []
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stop_motion = threading.Event()
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def mover():
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while not stop_motion.is_set():
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for ln in ('G0 X30 F3000', 'G0 Y8 F3000', 'G0 X-30 F3000', 'G0 Y-8 F3000'):
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g.s.sendall(ln.encode() + b'\n')
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g.wait_state('Idle', 20)
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if stop_motion.is_set():
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break
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time.sleep(0.2)
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def phase(label, fan, motion, dwell):
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t0 = time.time()
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if fan is not None:
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wr(aa, fan)
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th = None
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if motion:
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stop_motion.clear()
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th = threading.Thread(target=mover, daemon=True)
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th.start()
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end = t0 + dwell
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while time.time() < end:
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v = rd(SYSFS + 'head/air_assist_tach')
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tach.append((time.time(), int(v) if v and v.isdigit() else None))
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time.sleep(1.0)
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if th:
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stop_motion.set()
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th.join(25)
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g.wait_state('Idle', 20)
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phases.append((label, t0, time.time()))
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print(' %+7.1f s %s done' % (time.time() - phases[0][1], label), flush=True)
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try:
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phase('still, fan idle', None, False, 10)
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phase('fan run, still', 1023, False, 15)
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phase('fan run, jogging', None, True, 40)
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phase('fan run, still again', None, False, 10)
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phase('fan idle, jogging', 204, True, 30)
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phase('fan idle, still', None, False, 10)
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finally:
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stop_motion.set()
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try:
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g.wait_state('Idle', 20)
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g.cmd('G90')
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except Exception:
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pass
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if orig is not None:
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wr(aa, orig)
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time.sleep(2)
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sampler.stop.set()
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sampler.join(2)
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tr = sampler.samples
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print('\n%d samples, %.1f Hz' % (len(tr), (len(tr) - 1) / (tr[-1][0] - tr[0][0])))
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print('--- per phase: level toggles (both sensors, >= 0.45 C), the readings and the air-assist tach ---')
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print(' phase toggles down mean/sd up mean/sd tach mean/sd')
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rows = []
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for label, t0, t1 in phases:
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d = [degc(s[1]) for s in tr if t0 + 1 <= s[0] < t1 and s[1] is not None]
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u = [degc(s[2]) for s in tr if t0 + 1 <= s[0] < t1 and s[2] is not None]
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tk = [v for t, v in tach if t0 <= t < t1 and v is not None]
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sd = lambda v: (sum((x - sum(v) / len(v)) ** 2 for x in v) / len(v)) ** 0.5 if len(v) > 1 else 0.0
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tg = toggles(tr, t0 + 1.0, t1)
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rows.append({'phase': label, 'toggles': tg, 'down_mean': sum(d) / len(d) if d else None,
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'down_sd': sd(d), 'up_mean': sum(u) / len(u) if u else None, 'up_sd': sd(u),
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'tach_mean': sum(tk) / len(tk) if tk else None, 'tach_sd': sd(tk), 'dwell_s': t1 - t0})
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print(' %-26s %5d %6.2f/%.2f %6.2f/%.2f %s'
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% (label, tg, rows[-1]['down_mean'] or 0, sd(d), rows[-1]['up_mean'] or 0, sd(u),
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'-' if not tk else '%.0f/%.0f' % (rows[-1]['tach_mean'], sd(tk))))
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rec = {'drill': 'offset_probe_jog', 'date': time.strftime('%Y-%m-%dT%H:%M:%S'),
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'phases': rows, 'tach': tach, 'trace': tr}
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ddir = os.environ.get('FORGETEST_BENCH_DATA') or '/tmp'
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path = os.path.join(ddir, 'offset_jog_%s.json' % time.strftime('%Y%m%d-%H%M%S'))
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with open(path, 'w') as f:
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json.dump(rec, f)
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print('record: %s' % path)
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return 0
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def run_armed():
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"""An armed window with the tube dark: M3 S0 opens the window on the
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press (the fire level is zero, nothing is ever requested), a 60 s
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dwell, then M2. Phases: before the session / session open, waiting
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for the press / armed (the HV enable asserted) / after M2. Any lit
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sample (LASER_ON witness or tube current) soft-resets at once."""
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import json as _json
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import urllib.request
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from live_fire_drills import Grbl, HOST, PORT
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g = Grbl(HOST, PORT)
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st = g.status()
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if 'Idle' not in st:
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print('REFUSED: controller is %s, expected Idle' % st)
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return 2
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print('spindle off: %s' % g.cmd('M5'))
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def status():
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try:
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with urllib.request.urlopen('http://127.0.0.1:8080/status', timeout=2) as r:
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s = _json.load(r)
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with urllib.request.urlopen('http://127.0.0.1:8080/cool/status', timeout=2) as r:
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c = _json.load(r)
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return {'t': time.time(), 'armed': c.get('armed'), 'phase': c.get('phase'),
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'hv_enable': (s.get('switches') or {}).get('hv_enable'),
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'emission': (s.get('laser') or {}).get('emission_samples'),
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'hv': s.get('hv_current_raw')}
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except Exception:
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return None
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pre = status()
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if not pre or pre['armed']:
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print('REFUSED: forgectrl unreachable or the window is already armed (%s)' % pre)
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return 2
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print('>>> ARMED DARK DWELL: the button lights on the M3; press it. The fire level is')
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print('>>> zero and nothing is commanded; any lit sample soft-resets the job.')
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sampler = Sampler()
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sampler.start()
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poll = []
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lit = []
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stop = threading.Event()
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def poller():
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while not stop.is_set():
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s = status()
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if s:
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poll.append(s)
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if (s['emission'] or 0) > 0 or (s['hv'] or 0) > 20:
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lit.append(s)
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v = rd(SYSFS + 'cnc/laser_on_sampled')
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if v and v.isdigit() and int(v) > 0:
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lit.append({'t': time.time(), 'lon': int(v)})
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time.sleep(0.5)
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th = threading.Thread(target=poller, daemon=True)
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th.start()
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phases = []
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t_m3 = None
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try:
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time.sleep(8)
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phases.append(('before the session', sampler.samples[0][0], time.time()))
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print('G91/G21: %s / %s' % (g.cmd('G91'), g.cmd('G21')))
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t_m3 = time.time()
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for ln in ('M3 S0', 'G4 P60', 'M5', 'G90', 'M2'):
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g.s.sendall(ln.encode() + b'\n')
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# wait for the press: the engine's armed goes true
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t_armed = None
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deadline = time.time() + 300
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while time.time() < deadline and not lit:
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g.drain()
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if poll and poll[-1]['armed']:
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t_armed = poll[-1]['t']
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break
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time.sleep(0.2)
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if lit:
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raise RuntimeError('lit sample before the press: %s' % lit[:2])
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if t_armed is None:
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raise RuntimeError('no press within 300 s')
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phases.append(('session open, waiting for the press', t_m3, t_armed))
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print(' armed %.1f s after the M3' % (t_armed - t_m3), flush=True)
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# the dwell: armed, dark
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t_end = None
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while time.time() < t_armed + 75 and not lit:
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g.drain()
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if poll and not poll[-1]['armed'] and time.time() > t_armed + 5:
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t_end = poll[-1]['t']
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break
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time.sleep(0.2)
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if lit:
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raise RuntimeError('LIT SAMPLE DURING THE ARMED DWELL: %s' % lit[:2])
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t_end = t_end or time.time()
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phases.append(('armed, dark dwell', t_armed, t_end))
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print(' window closed %.1f s after the arm' % (t_end - t_armed), flush=True)
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time.sleep(20)
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phases.append(('after M2, fans still at run', t_end, time.time()))
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except Exception as e:
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print('ABORT: %s' % e)
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g.rt(b'\x18')
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time.sleep(2)
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finally:
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try:
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g.cmd('M5', timeout=1)
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except Exception:
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pass
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stop.set()
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sampler.stop.set()
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sampler.join(2)
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th.join(2)
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tr = sampler.samples
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print('\n%d samples, %.1f Hz; lit samples: %d' % (len(tr), (len(tr) - 1) / (tr[-1][0] - tr[0][0]), len(lit)))
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print('--- replies ---')
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for t, ln in g.log:
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if ln != 'ok':
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print(' %+7.1f s %s' % (t - (t_m3 or t), ln))
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print('--- hv_enable / armed transitions ---')
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last = None
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for p in poll:
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k = (p['hv_enable'], p['armed'])
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if k != last:
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print(' %+7.1f s hv_enable=%s armed=%s phase=%s' % (p['t'] - (t_m3 or p['t']), p['hv_enable'], p['armed'], p['phase']))
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last = k
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print('--- per phase: toggles, readings ---')
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print(' phase toggles down mean/sd up mean/sd')
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rows = []
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for label, t0, t1 in phases:
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d = [degc(s[1]) for s in tr if t0 + 1 <= s[0] < t1 and s[1] is not None]
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u = [degc(s[2]) for s in tr if t0 + 1 <= s[0] < t1 and s[2] is not None]
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sd = lambda v: (sum((x - sum(v) / len(v)) ** 2 for x in v) / len(v)) ** 0.5 if len(v) > 1 else 0.0
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tg = toggles(tr, t0 + 1.0, t1)
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rows.append({'phase': label, 'toggles': tg, 'down_mean': sum(d) / len(d) if d else None,
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'down_sd': sd(d), 'up_mean': sum(u) / len(u) if u else None, 'up_sd': sd(u), 'dwell_s': t1 - t0})
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print(' %-38s %5d %6.2f/%.2f %6.2f/%.2f'
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% (label, tg, rows[-1]['down_mean'] or 0, sd(d), rows[-1]['up_mean'] or 0, sd(u)))
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rec = {'drill': 'offset_probe_armed', 'date': time.strftime('%Y-%m-%dT%H:%M:%S'), 't_m3': t_m3,
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'phases': rows, 'poll': poll, 'lit': lit, 'replies': g.log, 'trace': tr}
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ddir = os.environ.get('FORGETEST_BENCH_DATA') or '/tmp'
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path = os.path.join(ddir, 'offset_armed_%s.json' % time.strftime('%Y%m%d-%H%M%S'))
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with open(path, 'w') as f:
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json.dump(rec, f)
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print('record: %s' % path)
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return 0 if not lit else 1
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def main():
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if len(sys.argv) > 1 and sys.argv[1] == 'jog':
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return run_jog()
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if len(sys.argv) > 1 and sys.argv[1] == 'armed':
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return run_armed()
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ladder = len(sys.argv) > 1 and sys.argv[1] == 'ladder'
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repeat = int(sys.argv[1]) if len(sys.argv) > 1 and not ladder else 2
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attrs = {
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'exhaust': SYSFS + 'thermal/exhaust_pwm',
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'intake': SYSFS + 'thermal/intake_pwm',
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'air_assist': SYSFS + 'head/air_assist_pwm',
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'purge': SYSFS + 'head/purge_air',
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'heater': SYSFS + 'thermal/heater_pwm',
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'pump': SYSFS + 'thermal/water_pump_on',
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'tec': SYSFS + 'thermal/tec_on',
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'lid_led': LEDS + 'lid_led/brightness',
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}
|
||||
orig = {k: rd(p) for k, p in attrs.items()}
|
||||
print('start values: %s' % orig)
|
||||
if orig['pump'] != '1' or orig['heater'] not in ('0', None):
|
||||
print('REFUSED: the pump is not on or the heater is not off (%s, %s)' % (orig['pump'], orig['heater']))
|
||||
return 2
|
||||
# (label, key, value, dwell)
|
||||
sched = [('baseline', None, None, 10)]
|
||||
if ladder:
|
||||
for duty in (256, 512, 768, 1023, 768, 512, 256):
|
||||
sched.append(('air assist %d/1023' % duty, 'air_assist', duty, 10))
|
||||
sched.append(('air assist idle', 'air_assist', 204, 10))
|
||||
for duty in (1023, 204, 1023, 204):
|
||||
sched.append(('air assist %d' % duty, 'air_assist', duty, 8))
|
||||
for _ in range(0 if ladder else repeat):
|
||||
sched += [('exhaust 100% (run, DC)', 'exhaust', 65535, 12), ('exhaust off', 'exhaust', 0, 12)]
|
||||
if not ladder:
|
||||
sched += [('exhaust 50% (PWM edges)', 'exhaust', 32768, 12), ('exhaust off', 'exhaust', 0, 12),
|
||||
('exhaust 25%', 'exhaust', 16384, 12), ('exhaust off', 'exhaust', 0, 12),
|
||||
('intake 66% (run)', 'intake', 43278, 12), ('intake off', 'intake', 0, 12),
|
||||
('air assist run', 'air_assist', 1023, 12), ('air assist idle', 'air_assist', 204, 12),
|
||||
('purge off', 'purge', 0, 8), ('purge on', 'purge', 1, 8),
|
||||
('heater 40%', 'heater', 26214, 8), ('heater off', 'heater', 0, 14),
|
||||
('pump off (dark, heater off)', 'pump', 0, 8), ('pump on', 'pump', 1, 12),
|
||||
('tec on', 'tec', 1, 6), ('tec off', 'tec', 0, 6),
|
||||
('lid lamp full', 'lid_led', 1023, 6), ('lid lamp back', 'lid_led', orig['lid_led'] or 0, 6),
|
||||
('all run fans', None, None, 0)]
|
||||
sampler = Sampler()
|
||||
sampler.start()
|
||||
edges = []
|
||||
try:
|
||||
for label, key, val, dwell in sched:
|
||||
if label == 'all run fans':
|
||||
t = time.time()
|
||||
wr(attrs['exhaust'], 65535)
|
||||
wr(attrs['intake'], 43278)
|
||||
wr(attrs['air_assist'], 1023)
|
||||
edges.append((t, label))
|
||||
time.sleep(15)
|
||||
t = time.time()
|
||||
wr(attrs['exhaust'], 0)
|
||||
wr(attrs['intake'], 0)
|
||||
wr(attrs['air_assist'], 204)
|
||||
edges.append((t, 'all fans off'))
|
||||
time.sleep(12)
|
||||
continue
|
||||
if key:
|
||||
t = time.time()
|
||||
wr(attrs[key], val)
|
||||
edges.append((t, label))
|
||||
print(' %+7.1f s %s' % (t - edges[0][0], label), flush=True)
|
||||
else:
|
||||
edges.append((time.time(), label))
|
||||
time.sleep(dwell)
|
||||
finally:
|
||||
for k, p in attrs.items():
|
||||
if orig[k] is not None:
|
||||
try:
|
||||
wr(p, orig[k])
|
||||
except OSError as e:
|
||||
print('RESTORE FAILED %s: %s' % (k, e))
|
||||
time.sleep(3)
|
||||
sampler.stop.set()
|
||||
sampler.join(2)
|
||||
tr = sampler.samples
|
||||
t0 = edges[0][0]
|
||||
print('\n%d samples, %.1f Hz' % (len(tr), (len(tr) - 1) / (tr[-1][0] - tr[0][0])))
|
||||
print('--- edges: common-mode step (1.5 s means after minus before), then toggles inside the dwell ---')
|
||||
print(' t(s) edge down step up step | common | toggles')
|
||||
rows = []
|
||||
for i, (t, label) in enumerate(edges):
|
||||
t_end = edges[i + 1][0] if i + 1 < len(edges) else tr[-1][0]
|
||||
b1, a1 = mean_c(tr, t - PRE - GAP, t - GAP, 1), mean_c(tr, t + GAP, t + GAP + POST, 1)
|
||||
b2, a2 = mean_c(tr, t - PRE - GAP, t - GAP, 2), mean_c(tr, t + GAP, t + GAP + POST, 2)
|
||||
d1 = None if None in (a1, b1) else a1 - b1
|
||||
d2 = None if None in (a2, b2) else a2 - b2
|
||||
common = (d1 is not None and d2 is not None and abs(d1) >= 0.4 and abs(d2) >= 0.4
|
||||
and (d1 > 0) == (d2 > 0))
|
||||
tg = toggles(tr, t + 2.0, t_end)
|
||||
rows.append({'t': t - t0, 'edge': label, 'down_step_c': d1, 'up_step_c': d2,
|
||||
'common': common, 'toggles': tg, 'dwell_s': t_end - t})
|
||||
print(' %6.1f %-28s %8s %8s | %-6s | %d'
|
||||
% (t - t0, label, '-' if d1 is None else '%+.2f' % d1,
|
||||
'-' if d2 is None else '%+.2f' % d2, 'YES' if common else '', tg))
|
||||
rec = {'drill': 'offset_probe', 'date': time.strftime('%Y-%m-%dT%H:%M:%S'), 'orig': orig,
|
||||
'edges': rows, 'trace': tr}
|
||||
ddir = os.environ.get('FORGETEST_BENCH_DATA') or '/tmp'
|
||||
path = os.path.join(ddir, 'offset_probe_%s.json' % time.strftime('%Y%m%d-%H%M%S'))
|
||||
with open(path, 'w') as f:
|
||||
json.dump(rec, f)
|
||||
print('record: %s' % path)
|
||||
print('end values: %s' % {k: rd(p) for k, p in attrs.items()})
|
||||
return 0
|
||||
|
||||
|
||||
if __name__ == '__main__':
|
||||
sys.exit(main())
|
||||
Reference in New Issue
Block a user