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XY microstep modes: the baseline, the catalog test and the bench tools
The baseline derives x/y_mode, step_freq, ramp_rate and the configured markers from the xy_microsteps setting; ramp_rate joins the GRBL controller's set (the driver writes it; the cloud client runs at the module's). motion.microstep-modes cycles 8, 16 and 32: the save restarts the idle controller, the kernel reads the mode with its tick and ramp, $100/$101 are the mode's and a typed $100 is overwritten, a 40 mm jog at top speed returns to Idle with the kernel counters over the mode agreeing with the commanded travel and the accelerometer seeing the head move; the setting is put back as found. Bench tools: xy_mode_test.py (the null-sink harness the grblHAL CI runs), raster_dry.py (a top-speed raster per mode), xy_pattern_accel.py (the operator's pattern from home with the machine silent and the head accelerometer listening), arc_tolerance_sweep.py (a $12 ladder on the 9 in circle: the chord rate the protocol loop feeds, about 300 a second, is the ceiling, not the core), and the xymode and xycircle live drills. BRINGUP carries the present state and the facts; CAMPAIGN-LOG the dated record, including the planner-blocks spin (a $398 of 255 or more loops forever at start, a core bug) and its recovery.
This commit is contained in:
ScottW514
+83
-4
@@ -142,7 +142,8 @@ core mutex stands in for interrupt masking. `GFSINK` unset = null-sink mode
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environment (on a Windows host, inside the WSL distro). Produces
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`build-arm/grblHAL_glowforge`
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in the checkout (`-O1 -g`; machine constants force-included into the core:
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53.333 µsteps/mm XY @ ×8, 2.832 half-steps/mm Z, 0.417" Z travel,
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53.333 µsteps/mm XY at ×8 (106.667 at ×16, 213.333 at ×32, the
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`xy_microsteps` setting, 8 by default), 2.832 half-steps/mm Z, 0.417" Z travel,
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12000 mm/min max, 700/590 mm/s² accel - factory-derived, see
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`puls_profile.py`).
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2. Deploy: move the new binary over `/usr/bin/grblHAL_glowforge` (mv replaces
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@@ -152,12 +153,14 @@ core mutex stands in for interrupt masking. `GFSINK` unset = null-sink mode
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3. Standalone start (bench/debug only - requires forgectrl stopped, since the
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broker's exclusive hold on `/dev/glowforge` makes any self-open fail EBUSY):
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`cd /data/forgefirm && GFSINK=/dev/glowforge grblHAL_glowforge -p 23 -e
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/data/forgefirm/EEPROM-glowforge.DAT`. Env knobs: `GFSINK_RATE` (machine
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tick, default 28160 Hz = factory travel tick), `GFSINK_DEPTH_MS` (queue
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/data/forgefirm/EEPROM-glowforge.DAT`. Env knobs: `GFSINK_RATE` (a machine
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tick override; the default is the `xy_microsteps` mode's: 28160 Hz at 8, the
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factory travel tick, 56320 at 16, 112640 at 32), `GFSINK_DEPTH_MS` (queue
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depth = feed-hold latency, default 200). Standalone, the driver opens the
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device itself and every takeover runs the `rail_settle_s` off-period; under
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the broker it inherits the fd and skips the settle (the rail never dropped). The driver
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applies the full analog machine config at init either way (×8 modes, decay 1,
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applies the full analog machine config at init either way (the `xy_microsteps`
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mode on both axes, 8 by default, with the tick and the stop ramp scaled to it; decay 1,
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motor_lock 0 with every axis in the pulse path and the Z soft limit always
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on, laser latched, PIC hold currents) and swaps PIC run/hold
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currents around motion. Each motion run logs a producer-stats line
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@@ -991,6 +994,40 @@ is committed.
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Travel moves peak 202 mm/s vector (≈ 8 in/s) at STfr=28160 Hz;
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prints and hunts run STfr=10000. Cut feed in the sample print: 145 mm/s. Z
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cadence ≈ 61–115 ms per half-step (≈ 5.7 mm/s max).
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- **XY microstep modes** (bench, dry, the hot-deployed driver and
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forgectrl): the machine holds its 200 mm/s top speed at 8, 16 and 32
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with the tick scaled (28160, 56320, 112640 Hz) and the stop ramp with it
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(125000, 250000, 500000 Hz/s). A 60-pass raster of 150 mm at F12000 (63 s)
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returns the kernel counters to dx = dy = 0.000 at every mode, with zero
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underruns and zero clamped events; the controller takes 25.6, 28.3 and
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35.0 percent of the core at 8, 16 and 32 during it, and 25.0, 25.6 and
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26.6 percent in `motion.step-timing-under-load` against the nice-5 hog.
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Every dry catalog motion test passes at every mode, drift 0.000 mm, the
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cancel's return exact. A mode change from the panel restarts the idle
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controller and the kernel reads the new mode about 2 s later. Under the
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laser (a 152.4 mm circle at S400 under M4 density at F2400, one per
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mode): the discharge window 12.0 s at every mode against 12.0 s
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expected, the HV current mean 402, 391 and 398 at 8, 16 and 32, dark
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after M5, zero underruns; the laser ticks scaled to the tick in force
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keep the pulse period a time, and the material shows it. By the head
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accelerometer with the machine silent (the quiet hold: every fan, the
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pump and the TEC off; a fixed 10 s wait; about 600 Hz over the bus at
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the crash watch's 4 g scale), over a pattern at F12000 from home (18 by
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9 in, a 9 in circle): the cruise RMS on the circle 2289, 1939 and 1638
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counts in X at 8, 16 and 32 (Y 1343, 1192, 1181), overall 1742, 1500 and
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1369 in X, the single-axis legs alike within a few percent, the rest
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floor about 50 (about 200 with the pump running: the pump is in the
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reading); the finer mode is the quieter one, most where both axes move.
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- **Arc chords**: grblHAL traces an arc as chords of sagitta `$12` (0.002 mm
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default), each a planner block, so a 9 in circle at F12000 is 531 chords
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of 1.35 mm and 148 block boundaries a second, an audible tone that no
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microstep mode changes. The protocol loop feeds about 300 chords a second
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at top speed with the planner kept full; above that (`$12` 0.00025 and
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finer on that radius) the feed sags mid-arc and the circle takes longer,
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with the CPU flat at 33 percent and no underrun, and a deeper planner
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buffer (`$398` 250) changes nothing. Finer chords move the tone up and
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do not lower the vibration. `$398` at 255 or more spins the controller
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at start (a core bug, "Next work"); the usable maximum is 254.
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- **Factory analog config** (constant across all captured jobs, 2018→2026):
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PIC currents X 135 run / 33 hold, Y 22 run / 5 hold (axis DAC scales differ by
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design); x/y_decay=1; ×8 microstepping; run currents applied only while
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@@ -1425,6 +1462,48 @@ feature requests, enhancements) will eventually be tracked as GitHub issues.
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far): re-measure the two heat coefficients and the machine's
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air-assist offset; and if a lit check still trips, the
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void-on-emission design with the tube as its own flow tracer.
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8. **XY microstep modes (8, 16, 32).** One setting, `xy_microsteps`, is
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the XY scale: the GRBL controller reads it at its start and derives
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`$100`/`$101`, its machine tick (28160 Hz at 8, doubled at 16,
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quadrupled at 32) and the kernel stop ramp from it, forgectrl admits
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the three values and restarts an idle GRBL controller on a change, and
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the catalog's `motion.microstep-modes` cycles the modes. Host-proven
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(the driver's `xy_scale_test` and the `xy_mode_test.py` harness, the
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forgectrl and forgetest unit tests, the coverage lint) and dry
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bench-proven at all three modes on the hot-deployed binaries: the
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catalog test, `motion.step-timing-under-load`, `motion.pacing` and
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`motion.cancel-abort` at each mode, and a 60-pass top-speed raster
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(`scripts/bench/raster_dry.py`) at each, every counter back to its
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start, zero underruns, zero clamped events, the controller at 25 to
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35 percent of the core, and live under the laser at all three modes
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(a 152.4 mm circle at S400 F2400 per mode, the HV current at cruise
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alike across them, the operator's verdict "perfect" on each; the
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facts bank has the numbers, `scripts/bench/live_fire_drills.py`
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`xymode` and `xycircle` are the drills), and by the head
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accelerometer with every fan off (`scripts/bench/xy_pattern_accel.py`
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through the new `POST /cool/quiet`): the vibration at 200 mm/s falls
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with the finer mode, most on a circle (x RMS down 29 percent at 32).
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Uncommitted. Owed: the commits, pins, image and campaign. 32 is admitted; the
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fallbacks, should another machine not hold it, are the 84480 Hz tick
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or the `$110` ceiling the driver holds under a lower tick. Cloud mode
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runs at the service's own 8: the service plans every stream at 8
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whatever the machine reports (the machine reports 1, as the factory
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firmware does, and every header comes back 8), and the cloud client
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now refuses a header at any other mode before a byte reaches the
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ring, the way it refuses a wrong serial or format. Finer modes in
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cloud mode (a local stream expander in the feeder, or the service
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planning finer) wait for a user's report of such a refusal, by
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decision.
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9. **Planner buffer of 255 blocks or more spins the controller.** The
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core's `plan_reset_buffer()` links the block ring with a `uint_fast8_t`
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index, so `$398` at 255 or more never finishes at start: the main
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thread sits at 100 percent in `plan_reset()`, the Grbl port stops
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answering, and forgectrl still reports the controller running (the
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supervisor sees deaths and silent armed reporters, not an idle spin).
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Reproduced on the host build. Owed in the fork (openglow-org
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grblHAL-core, branch forgefirm): the index widened to `uint_fast16_t`,
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or the sanity check capped at 254, and a host test that starts the
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null-sink build with `$398=400`. Until then the usable maximum is 254.
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**Deliberately not gated:** an armed GRBL job after an underrun cuts at the
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stale origin unless homing is required (GRBL mode permits unhomed cutting; the
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@@ -9336,6 +9336,211 @@ emergency lever, and it safes the machine with `cnc/stop` and the latch
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before the signal instead. The mode switch, the cooling gate and the daemon
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shutdown do gate on `machine_is_idle()`, which reads `cnc/state`.
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## 2026-09-07: XY microstep modes 8, 16 and 32, dry bench proof
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One setting, `xy_microsteps`, became the XY scale in GRBL mode: the driver
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derives `$100`/`$101`, its machine tick (28160 Hz at 8, 56320 at 16,
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112640 at 32) and the kernel stop ramp (125000, 250000, 500000 Hz/s) from
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it, forgectrl admits the three values and restarts an idle GRBL controller
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on a change, and the catalog gained `motion.microstep-modes`. Host proof
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first: the driver's `xy_scale_test` and the `xy_mode_test.py` null-sink
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harness, the forgectrl and forgetest unit tests, and the coverage lint (82
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tests, 0 uncovered). Then the bench, 18:27 to 18:45Z, on image
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20260907005922 (dev) with the cross-built forgectrl (sha256 01ed40d3) and
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driver (83893a00) hot-deployed through `/etc/init.d/forgectrl stop` and
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`start`, and the forgetest files with a forgetest restart (queue idle;
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catalog 82 tests).
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- `motion.microstep-modes` PASS in 24 s: at 8, 16 and 32 the kernel read
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the mode on both axes with the mode's tick and ramp, `$100`/`$101` were
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the mode's, a typed `$100=53.333` came back as the mode's value on the
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spot, a 40 mm jog at F12000 measured 39.990, 40.000 and 40.000 mm by the
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kernel counters, drift 0.000, and the head accelerometer saw the head on
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every leg. The first attempt failed on the test itself (it read the
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counters before the kernel had played out the queue behind grblHAL's
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Idle); the test now waits for the machine to be idle first.
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- `motion.step-timing-under-load`, `motion.pacing` and
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`motion.cancel-abort` PASS at every mode. The controller under the
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nice-5 hog: 25.0, 25.6 and 26.6 percent of the core at 8, 16 and 32;
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zero clamped events; `cnc/underruns` 0 throughout; the pacing move
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30.000 mm with drift 0.000; the cancel's return exact.
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- The dry raster (`scripts/bench/raster_dry.py`, 60 passes of 150 mm at
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F12000 with the laser off, 63 s per mode) PASS at every mode: the kernel
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counters back to dx = dy = 0.000, Grbl drift 0.0, zero underruns, zero
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clamped events; controller CPU 25.6, 28.3 and 35.0 percent at 8, 16
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and 32.
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- A mode change from the panel restarts the controller and the kernel
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reads the new mode about 2 s later; each switch in the drills settled in
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2 s.
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**Live fire, 19:03 to 19:12Z, operator present, one armed run per turn,
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the button pressed by the operator for each.** Two new drills in
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`scripts/bench/live_fire_drills.py`: `xymode` (a 20 mm out-and-back line
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pair per feed, F1200 and F6000, at S400 under M4 density) and `xycircle`
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(a 152.4 mm circle from its top at S400 under M4 density at F2400, the
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operator's request for something the eye can follow), each a dark rapid
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+X by an offset first and a rapid back to the origin after. The mode was
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set from the settings before each run (the controller restarted, the
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kernel at the new mode within 2 s each time).
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| Run | Mode, tick, ramp | Lit | HV current mean | Thermopile mean |
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|---|---|---|---|---|
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| line pair at offset 0 | x8, 28160 Hz, 125000 Hz/s | 2.1 s (F1200), 0.7 s (F6000) | 385, 382 | 2621, 2197 |
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| circle at 76.2 mm | x8, 28160 Hz, 125000 Hz/s | 12.0 s (12.0 expected) | 402 | 2558 |
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| circle at 101.6 mm | x16, 56320 Hz, 250000 Hz/s | 12.0 s | 391 | 2570 |
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| circle at 127 mm | x32, 112640 Hz, 500000 Hz/s | 12.0 s | 398 | 2507 |
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Every run: one discharge window (two for the line pair), dark after M5
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(HV max 0), `cnc/underruns` 0, the machine idle with the latch locked
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after. The HV current at cruise reads alike at the three modes, which is
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what the scaling of the laser ticks to the tick in force was built to
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give; the operator judged each circle "perfect" against the one before.
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No scope check of the FIRE period: the operator ruled the arithmetic
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sufficient (the period is the reference ticks times the tick ratio, a
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whole number at every mode).
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**The head accelerometer, every fan off, 19:29 to 19:36Z.** forgectrl
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gained `POST /cool/quiet` (the engine's quiet hold the commissioning finder
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uses, now reachable by the bench tools; taken only from an idle machine,
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released by the engine when a run session opens or after 600 s; `/cool/status`
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shows `quiet_hold`), hot-deployed (sha256 051804c4) and exercised: the air
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assist, exhaust, intake and purge all read 0 while held and came back to the
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idle posture on release. The machine was homed (`$H`, 48 s, `H:1`, Z 3.080)
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and `scripts/bench/xy_pattern_accel.py` ran the operator's pattern at each
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mode: from home to (18, 9) in, to (9, 9) in, a 9 in circle from its
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mid-bottom back to (9, 9), to (9, 0), home, every leg at F12000, the fans
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held quiet with the fixed 10 s wait, the head accelerometer read over the
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bus at about 600 Hz (CTRL4 0x04, the crash watch's 4 g scale) and the
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cruise windows trimmed 0.35 s at each end. Every leg reached 12000 mm/min
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and ended on its waypoint to 0.003 mm; the circle took 3.87 s at every
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mode; the kernel counters came back to dx = dy = 0.000; underruns 0.
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| Cruise RMS (raw counts, mean removed) | x8 | x16 | x32 |
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|---|---|---|---|
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| at rest, fans off | x 197, y 123 | x 213, y 129 | x 246, y 138 |
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| the diagonal to (18, 9) | x 1093, y 1100 | x 1083, y 1076 | x 1055, y 1078 |
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| the 9 in circle | x 2210, y 1392 | x 1832, y 1189 | x 1573, y 1166 |
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| the return legs (mean of three) | x 1145, y 1073 | x 1045, y 1076 | x 1005, y 983 |
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| overall | x 1693, y 1231 | x 1458, y 1133 | x 1317, y 1098 |
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The vibration at speed falls with the finer mode on every leg that moves
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both axes, most on the circle (x RMS down 17 percent at 16 and 29 percent
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at 32 against 8; the peak-to-peak on the circle 21229, 18141, 12480); the
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single-axis legs sit within a few percent of each other. The records with
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the raw traces are beside the image under `images/20260907005922/bench-data/`.
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**The same pattern with the machine silent, 19:45 to 19:49Z.** The operator
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asked for the coolant pump off too, so the modes could be heard: the quiet
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hold now takes every fan, the pump and the TEC (forgectrl sha256 38b79727,
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hot-deployed; the tick leaves the TEC alone while the hold stands and
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rewrites it at the release; the pump comes back at the release). The rest
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floor with the pump off is a quarter of what it was with it on (x RMS 50,
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57 and 52 counts at 8, 16 and 32 against about 200 before: the pump was in
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the reading), and the pattern gave the same picture:
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| Cruise RMS (raw counts, mean removed), pump off | x8 | x16 | x32 |
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|---|---|---|---|
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| the diagonal to (18, 9) | x 1111, y 1134 | x 1038, y 1101 | x 1097, y 1110 |
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| the 9 in circle | x 2289, y 1343 | x 1939, y 1192 | x 1638, y 1181 |
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| overall | x 1742, y 1209 | x 1500, y 1110 | x 1369, y 1118 |
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Every leg again at 12000 mm/min, ending on its waypoint, the circle 3.88 s
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at every mode, the kernel counters back to zero, underruns 0, and the idle
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posture back after each release (air assist 204, purge on, pump on). The
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machine was homed again first (`$H`, 51 s) because the forgectrl restart
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had dropped the homed flag.
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**How fine an arc, 19:55 to 20:40Z.** The circle sounded the same at every
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mode, with the same harmonic through parts of the arc, and the arithmetic
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says why: grblHAL traces an arc as chords whose sagitta is `$12`, every
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chord a planner block, so the 9 in circle at F12000 under the default
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0.002 mm is 531 chords of 1.35 mm and 148 block boundaries a second, a
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148 Hz tone that the planner's geometry makes and the motor's step grid
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cannot change. `scripts/bench/arc_tolerance_sweep.py` ran a `$12` ladder on
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the circle at x16, the machine silent, to see how far down the one core
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takes it:
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| `$12` | Chords | Boundaries/s | Circle | Lowest mid feed | Free planner blocks (of 100) | CPU | Circle X RMS |
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|---|---|---|---|---|---|---|---|
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| 0.002 | 531 of 1.35 mm | 148 | 3.86 s | 12000 | 0 to 77 | 32.6 % | 1823 |
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| 0.001 | 751 of 0.96 mm | 209 | 3.85 s | 12000 | 0 to 65 | 33.0 % | 1815 |
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| 0.0005 | 1062 of 0.68 mm | 296 | 3.87 s | 12000 | 0 to 45 | 33.1 % | 1835 |
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| 0.00025 | 1502 of 0.48 mm | 418 | 3.89 s | 10592 | 0 to 23 | 33.2 % | 1911 |
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| 0.0001 | 2374 of 0.30 mm | 661 | 4.13 s | 6220 | 0 to 2 | 33.2 % | 2262 |
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No clamped events and no underrun at any rung; the CPU flat at 33 percent
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all the way down, so the core is not what runs out. Above about 300
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chords a second the feed sags mid-circle and the circle takes longer: the
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planner plans to a stop at the end of what it holds, and with 100 blocks of
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0.3 mm it holds 30 mm against a 29 mm stopping distance from 200 mm/s.
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Finer chords did not lower the vibration; the tone moved up (148, 209,
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296 Hz) and the RMS stayed put, then rose where the feed sagged. The same
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ladder with `$398` raised to 250 blocks gave the same numbers (10706 and
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6355 mm/min at the two failing rungs, the buffer never more than about 80
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blocks full, CPU 34 percent): the chord rate the protocol loop feeds is the
|
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ceiling, not the buffer depth and not the core. The finest `$12` that holds
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||||
top speed on this radius is 0.0005; at a lower feed a finer value holds in
|
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proportion, and a smaller radius reaches the same chord rate sooner. The
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records (the 100-block ladder) are beside the image under
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`images/20260907005922/bench-data/`.
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Two findings on the way. A trial launched with `$398=400` left the
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||||
controller spinning at start: the core's `plan_reset_buffer()` links the
|
||||
block ring with a `uint_fast8_t` index, so a buffer of 255 blocks or more
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never finishes (the sanity check allows up to 1000). The main thread sat
|
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at 100 percent in `plan_reset()`, the port's backlog filled and connects
|
||||
timed out, and forgectrl kept reporting the controller running and
|
||||
verified. Reproduced on the host null-sink build under gdb. Recovered by
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stopping the controller through forgectrl, rewriting the planner-blocks
|
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value and the block's Modbus CRC-16 in the settings store, and starting
|
||||
it again. The fork owes the one-line fix (`uint_fast16_t`); until then the
|
||||
usable maximum is 254, and the deeper-buffer trial ran at 250. And the
|
||||
launch that wrote 400 was a remote command the operator had rejected at
|
||||
the prompt: the process on the board had already started and ran on as an
|
||||
orphan, which is a rule for the bench now (check the board after any
|
||||
rejected or interrupted remote command before re-issuing).
|
||||
|
||||
**The pre-commit review of the catalog, 20:40 to 20:55Z.** Read against
|
||||
every change, it turned up four things, each fixed and proven before any
|
||||
commit. The quiet hold had taken the pump for the commissioning finder as
|
||||
well, which was proven with the pump running: the hold is now two levels,
|
||||
every fan off (`cool_quiet_hold`, the finder's) and the pump and the TEC
|
||||
too only on request (`POST /cool/quiet?on=1&pump=1`, the bench tools').
|
||||
The engine's release of the hold on a run session had been level-triggered,
|
||||
which would have dropped the finder's hold after a burn when the
|
||||
controller's report still said run; it now fires on the session's opening
|
||||
edge (the flood rising or the armed window opening), verified on the bench
|
||||
by taking the pump hold and sending `M8`: the hold released within 3 s
|
||||
and the pump came back. The forgetest baseline had kept `cnc/ramp_rate`
|
||||
among the values it holds in every mode, while the driver now writes it
|
||||
and the cloud client runs at the module's; it is in the GRBL controller's
|
||||
set now, skipped in cloud mode. And the forgectrl dev mock is held to the
|
||||
daemon's tables by a unit test, so the new setting and the new route
|
||||
needed their mock entries, and the bench README lists every tool. Also
|
||||
checked: the docs site builds clean under strict mode, the style check is
|
||||
clean, the coverage lint is clean, every host test passes (the driver's
|
||||
five C tests and four harnesses, forgectrl's eight C tests and the mock
|
||||
parity test, forgetest's suite), and the deployed forgectrl (sha256
|
||||
323a7d14) shows both hold levels and the release on the bench.
|
||||
|
||||
**Cloud mode, decided at 21:05Z.** The captures say the service plans
|
||||
every stream at 8 and writes 8 into every header (23 of 23 here, the
|
||||
factory captures the same) while the machine reports 1, so the reported
|
||||
value is not what it plans with. The operator does not expect the service
|
||||
to plan finer, so the cloud client now refuses a header whose `XSmm` or
|
||||
`YSmm` is anything but 8, with the serial and format checks, before a byte
|
||||
reaches the ring; a header without the tags runs at 8. Host-proven in
|
||||
`gfutilities` (`test_puls_header.py`); finer modes in cloud mode wait for a
|
||||
user's report of such a refusal.
|
||||
|
||||
Left after the session: the board in GRBL mode at 8 with the key cleared,
|
||||
`$12` 0.002 and `$398` 100 as found, homed, `/tmp` clean, `/data` holding
|
||||
only factory state and ForgeFIRM's own files, the hot-deployed binaries in
|
||||
place until the next flash. Cloud mode was left at the service's own 8 by
|
||||
decision: the service plans every stream at 8 whatever the machine
|
||||
reports. Nothing committed at the time of writing: the operator's order is
|
||||
no commit until the code is proven, and the commit is the operator's call.
|
||||
|
||||
## Reference notes
|
||||
|
||||
### Head-IRQ source validation — the beam-emission hypothesis
|
||||
|
||||
Reference in New Issue
Block a user