Docs: corrected coolant curve and the rebuilt flow check

Records why the temperature formula changed (and that everything derived from the old one had to be re-derived), the flow characterization data at both heater duties, the false negative that killed the dT-threshold design, and the downstream-rise check that replaced it. Adds flow_characterize.py to the bench kit.
2026-09-27 08:41:13 -07:00 · 2026-08-02 19:12:00 -04:00
parent 3d1c9edfeb
commit 8fa10f7b28
3 changed files with 152 additions and 8 deletions
@@ -232,14 +232,35 @@ hardware I/O — host testing).
     it to a hard fire gate). Verified via tach readbacks: air tach
     period 4439→699 under M8, exhaust stopped→full, intakes ~3×,
     cooldown hold, clean return to idle; coolant temp visibly
-     dropped during the blast. **Coolant flow verification also DONE**
-     (the factory heater trick: loop heater at 10 % between the two
-     water-temp sensors; measured on this machine — flow ΔT settles
-     +2.5..4.0 °C and never sustains >4.1, pump-stopped ΔT hits
-     +4.6..5.7 within 20 s; fault = ΔT>4.5 °C for 20 s, live-verified:
-     pump stopped → sender warning in 40 s → recovery re-arms).
-     Absolute ceiling 33 °C (job-header CMrx; heater adds ~1.5 °C to
-     the loop). **v2 (same day): heater job-scoped** (M8..M9 only — an
+     dropped during the blast. Absolute ceiling 33 °C (job-header
+     CMrx).
+
+     **Coolant temperature conversion CORRECTED 2026-08-02** — the
+     UAPI "best guess" `raw*-0.09653+94` was wrong (3–5 °C high, wrong
+     slope); the real one is the factory B-equation recovered from the
+     v2.6.0 binary (10 k B3380 NTC, 10 k divider, ×1.3 gain, 10-bit
+     ADC), proven by reproducing this machine's `WT*` cloud settings
+     exactly, and thermometer-checked to ~1 °C. Full derivation now in
+     `kernel-module-glowforge/UAPI.md`. Consequence: the 33 °C ceiling
+     had been firing at a real ~29 °C, and **anything derived from the
+     old formula had to be re-derived** — which is how the flow check
+     below got rebuilt.
+
+     **Coolant flow verification (rebuilt, live-verified both ways).**
+     Continuous 10 % heating was never viable on the corrected curve:
+     flow ΔT ≤3.69 vs no-flow ΔT ≥3.74 — a 0.04 °C gap against ~0.9 °C
+     of sensor noise. At 30 % the ΔT bands separate (≤9.32 / ≥10.99)
+     but a ΔT threshold still **failed a live pump-off drill** (8.8 °C
+     vs a 10.2 °C limit), because a check starting from a cold heater
+     never reaches the steady-state delta. Final design: a **one-shot
+     check at job start (M8)** — heater to 30 % for 50 s — with the
+     discriminator being **downstream temperature RISE** (flow ≈10.3 °C
+     vs no-flow ≈15.1 °C, ~6 °C separation; threshold 12.7 °C,
+     `GFCOOL_FLOW_RISE`). Heater goes off afterwards, so the loop is
+     not warmed for the rest of the job, and absolute over-temp
+     monitoring carries protection from there (a pump failure mid-cut
+     shows as a temperature climb far faster than any heater delta).
+     Verified twice each way from a cooled loop. **v2 (same day): heater job-scoped** (M8..M9 only — an
     always-on heater eats headroom below the 31 °C start gate at
     idle; flow faulting arms 30 s after heater-on), **two-phase
     cooldown** (15 s smoke clear at run duty, then half-duty airflow
@@ -12,6 +12,8 @@ target board (dev image, python3 present) unless noted.
 | `pwm_hold.py` | Holds one PWMSAR value for a scope-measurement window (`pwm_hold.py <sar> <seconds>`), then restores. Same locked-state rule. |
 | `fire_test.py` | FIRE drop-timing scope test (runs on the board): A = latch locked (expects nothing on FIRE/LASER_ON), B = latch unlocked / normal end-of-data, U = true underrun. Duty 0 throughout; refuses to unlock if HV reports good. All gates PASSED with it 2026-08-02 (2.0000 s pulses exact, both paths). |
 | `fan_test.py` | Fan/coolant bench (Windows-side): snapshots fan PWMs/tachs/temps, drives M8 → cut fans, M9 → cooldown → idle, verifying via tach readbacks. All-green 2026-08-02. |
+| `flow_characterize.py` | Coolant flow characterization using the factory temperature curve: baseline → flow → no-flow → recovery, printing the ΔT bands and their separation. Takes the heater duty as an argument (`flow_characterize.py 30`); aborts if downstream passes 45 °C. This is what showed the 10 % scheme was unusable (0.04 °C gap) and sized the 30 % check. |
+| `temp_calibrate.py` | Coolant temperature calibration helper (`watch` / `point <measured_C>` / `fit`) — pairs a measured temperature with averaged raw ADC readings and fits the line. Used to sanity-check the factory curve against a thermometer. |
 | `build-glowforge.sh` | Cross-compiles **grblHAL-glowforge** (the canonical driver repo, `../../../grblHAL-glowforge`) in the forge-yocto WSL distro. Run: `wsl -d forge-yocto -- bash <path>/build-glowforge.sh` (from PowerShell; Git Bash mangles /mnt/c paths). This is the production controller build. |
 | `build-feeder.sh` | Cross-compiles `feeder.c` the same way. |
 | `puls_profile.py` | Decodes factory `.puls` streams (raw or GF1-headered) into velocity/accel profiles: peak speeds, ramp-slope fits, per-move segments, Z cadence. Runs anywhere (stdlib only). Source of the factory-true grblHAL defaults (milestone 2): 700/590 mm/s² accel, 200 mm/s max rate, 28160 Hz travel tick. |
@@ -0,0 +1,121 @@
+#!/usr/bin/env python3
+"""Characterize the coolant flow signature using the FACTORY temperature
+curve, and recommend flow-fault thresholds.
+
+The loop heater sits between the two water sensors; flowing coolant
+carries its heat away, so downstream-minus-upstream settles at a small
+stable delta. Stopping the pump lets that heat pool, and the delta
+climbs. This measures both signatures and prints the separation.
+
+Phases: baseline (heater off) -> flow (heater on, pump on) -> no-flow
+(pump off) -> recovery (pump on). Restores heater off / pump on.
+
+Run with the controller stopped, or accept that it will fight you: the
+driver only writes the heater on M8/M9 transitions, so an idle driver
+leaves this alone.
+"""
+import math
+import subprocess
+import sys
+import time
+
+HOST = '172.16.1.97'
+
+# Factory B-equation conversion (see kernel-module-glowforge/UAPI.md).
+F = 1024.0 * 1.3
+RD = 10000.0
+BETA = 3380.0
+RINF = 10000.0 * math.exp(-3380.0 / 298.15)
+
+
+def degc(raw):
+    if raw <= 0 or raw >= F:
+        return float('nan')
+    r = RD / (F / raw - 1.0)
+    return BETA / math.log(r / RINF) - 273.15
+
+
+def board(cmd):
+    r = subprocess.run(['wsl', '-d', 'forge-yocto', '--', 'ssh',
+                        '-o', 'PreferredAuthentications=none',
+                        'root@' + HOST, cmd],
+                       capture_output=True, text=True, timeout=30)
+    return r.stdout.strip()
+
+
+def sample():
+    out = board('cat /sys/glowforge/pic/water_temp_1 /sys/glowforge/pic/water_temp_2').split()
+    if len(out) != 2:
+        return None
+    d, u = degc(int(out[0])), degc(int(out[1]))
+    return d, u, d - u
+
+
+DOWN_ABORT_C = 45.0   # never cook the loop while characterizing
+
+
+def phase(tag, seconds, interval=10, settle=0):
+    """Log a phase; return the deltas after the settle period."""
+    t0 = time.time()
+    keep = []
+    while time.time() - t0 < seconds:
+        s = sample()
+        if s:
+            el = time.time() - t0
+            print('  %-7s t=%3.0fs  down=%5.2f  up=%5.2f  dT=%+5.2f'
+                  % (tag, el, s[0], s[1], s[2]), flush=True)
+            if el >= settle:
+                keep.append(s[2])
+            if s[0] >= DOWN_ABORT_C:
+                print('  ABORT: downstream %.1f C >= %.1f C safety limit'
+                      % (s[0], DOWN_ABORT_C), flush=True)
+                board('echo 1 > /sys/glowforge/thermal/water_pump_on; '
+                      'echo 0 > /sys/glowforge/thermal/heater_pwm')
+                break
+        time.sleep(interval)
+    return keep
+
+
+def stats(name, ds):
+    if not ds:
+        print('%s: no samples' % name)
+        return None, None
+    print('%s: n=%d  min=%+.2f  max=%+.2f  mean=%+.2f'
+          % (name, len(ds), min(ds), max(ds), sum(ds) / len(ds)))
+    return min(ds), max(ds)
+
+
+heater_pct = int(sys.argv[1]) if len(sys.argv) > 1 else 10
+heater_pwm = str(int(65535 * heater_pct / 100))
+
+print('=== baseline: heater off, pump on (60 s)')
+board('echo 1 > /sys/glowforge/thermal/water_pump_on; echo 0 > /sys/glowforge/thermal/heater_pwm')
+base = phase('base', 60, 10, 30)
+stats('baseline dT', base)
+
+print('=== flow: heater %d%%, pump on (240 s; first 60 s ignored while dT establishes)' % heater_pct)
+board('echo ' + heater_pwm + ' > /sys/glowforge/thermal/heater_pwm')
+flow = phase('flow', 240, 10, 60)
+fmin, fmax = stats('flow dT', flow)
+
+print('=== no-flow: pump OFF, heater still on (150 s; first 20 s ignored)')
+board('echo 0 > /sys/glowforge/thermal/water_pump_on')
+noflow = phase('noflow', 150, 10, 20)
+nmin, nmax = stats('no-flow dT', noflow)
+
+print('=== recovery: pump on, heater off (90 s)')
+board('echo 1 > /sys/glowforge/thermal/water_pump_on; echo 0 > /sys/glowforge/thermal/heater_pwm')
+phase('recov', 90, 15)
+
+print()
+if fmax is not None and nmin is not None:
+    print('flow band:    up to %+.2f C' % fmax)
+    print('no-flow band: from %+.2f C' % nmin)
+    if nmin > fmax:
+        fault = (fmax + nmin) / 2.0
+        print('separation:   %.2f C  -> suggested fault threshold %.2f C, re-arm %.2f C'
+              % (nmin - fmax, fault, fault - 0.4))
+    else:
+        print('BANDS OVERLAP - flow detection unreliable at %d%% heater; try a higher duty'
+              % heater_pct)
+print('restored: pump on, heater off')