diff --git a/docs/BRINGUP.md b/docs/BRINGUP.md index 214b9f5..2d27b02 100644 --- a/docs/BRINGUP.md +++ b/docs/BRINGUP.md @@ -355,7 +355,7 @@ factory 2.6.0-2228 session; measured numbers in the facts bank). alike: the retrace is sized to `cnc/max_backtrack` and the lead follows it, so a pause with little history behind it shortens both rather than failing. GRBL mode uses feed hold / cycle start, so a resumed GRBL cut picks up where - the deceleration ended (item 15). A pause is not a cancel: the latch + the deceleration ended (item 14). A pause is not a cancel: the latch stays unlocked and the window open across it. There is no resume dwell: the safing chain re-arms ~216 ms before the first step (facts bank). - **`lid_policy = hold`** selects stock grblHAL door behavior instead (park in @@ -961,7 +961,9 @@ is committed. it had to be re-derived. The flow check's bands hold from 19 to 27 C, the loop heater's ceiling in a 20 C room, with the margin widening warm; above that only a running tube warms the loop, and the check takes the tube's - share off. + share off. With the pump on, a heater slug reaches the upstream sensor + within seconds and inflates the instant reading by a degree; the warm-up + release therefore judges a one-minute rolling minimum of that reading. - **The four `pic/lid_ir_*` channels are first of all a photometer for the lid lamp.** Measured against `lid_led` (sysfs brightness, 0 to 1023): all four channels follow it as a straight line, 2 counts dark, 32 to 35 at 128, 54 to @@ -1099,16 +1101,7 @@ is committed. Open items only. Anything closed is in `CAMPAIGN-LOG.md`. -1. **Low-temperature gates and warm-up (planned).** Two keys in the Cooling - card: `cool_temp_min` (hard floor, default ~5 °C, a fire gate) and - `cool_temp_start` (warm-up gate, default ~16 °C) — a job starting below the - gate holds in a factory-style warm-up phase with the loop heater on and - releases above it; below the floor nothing fires. Rationale: cold-tube - thermal shock, condensation when the TEC pulls below the dew point, frozen - coolant. Sequencing: warm-up first, flow check after. Measured physics on - this bench: 50 % duty warms the bulk ~0.5–0.8 °C/min and plateaus ~8–9 °C - above ambient — the same unaided limit the factory has. -2. **TEC handling (planned).** `thermal/tec_on` is a bare on/off output with no +1. **TEC handling (planned).** `thermal/tec_on` is a bare on/off output with no readback, so presence cannot be detected: it becomes a `tec_present` user setting (Machine tab, default off; ForgeFIRM never drives `tec_on` unless set), which also covers retrofits. Operation when present: simple hysteresis @@ -1120,7 +1113,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. all is a spec-level claim (Glowforge ships it on the Pro; Basic/Plus use the same passive closed-loop cooling), not teardown-verified per unit — another reason it is a setting. -3. **Fire watch (lid IR) redesign.** The gate stays disabled +2. **Fire watch (lid IR) redesign.** The gate stays disabled (`cool_fire_ir_delta = 0`) until it is lamp-aware: the engine must own or observe the lamp level (suspend the watch and re-baseline for a few ticks after any `lid_led` change) and the threshold must be relative to the @@ -1143,11 +1136,11 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. cloud job carries. By decision those header thresholds (`IR??`) are the prior for this redesign and nothing else: the cloud client declares them ignored, and the watch stays disabled until it is lamp-aware. -4. **Limit-switch homing.** The planned second homing method (`$22` stays 0 +3. **Limit-switch homing.** The planned second homing method (`$22` stays 0 until it lands); printable brackets are in `3d-models/`. Also: calibrate `gfcloud_home_x/y` against a jog to a known reference if the factory corner offset matters. -5. **Cameras.** **First light on an 8 MP (OV8856) machine**: the +4. **Cameras.** **First light on an 8 MP (OV8856) machine**: the whole path is written but nothing has run on one, and only that hardware can answer whether the 2-lane RAW8 full-resolution mode locks the D-PHY at 720 Mbps/lane and what exposure/gain the sensor wants; the details, the @@ -1162,7 +1155,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. no register file. No shipped machine applies a per-unit shading table, so ForgeFIRM owes none. Finally the deferred emulator homing-image smoke, now that the emulator can be pointed at live snapshots. -6. **Cloud mode.** A print is no longer capped by the ring: the client holds +5. **Cloud mode.** A print is no longer capped by the ring: the client holds the compressed body, fills the ring before the button, and tops it up as it plays, with the body bounded by `pulse_reject_threshold_bytes` because memory is what that costs. A feed that wedges is caught by progress rather @@ -1204,7 +1197,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. the cancel-with-a-rejected-`settings`-action case, a malformed frame (needs a MITM), a body past the memory guard (the service has no such job to send), and a wedged feed (a healthy machine will not stall on request). -7. **Shared machine services — remaining polish.** None of it blocking: +6. **Shared machine services — remaining polish.** None of it blocking: - **Diagnostics as engine modes.** The flow tools still drive the thermal hardware themselves while the engine suspends its writes; the check parameters are already shared (`cool.h`), so what remains is folding the @@ -1220,26 +1213,26 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. `ensure_engine` `popen()`s should move out of the HTTP callback so a slow media-ctl cannot stall the request thread. Changing the MHD start flags touches the streaming model, so this wants a bench slot of its own. -8. **Physical-evidence negatives still open.** A present head answering I²C +7. **Physical-evidence negatives still open.** A present head answering I²C badly (the K-11 runtime case) and a failed head capture leaving the measure laser off — both need the head connected and a fault injected. Opportunistic: `STATE_FAULT` recovery via `enable` the next time a DRV8825 fault line actually trips. -9. **Debug-kernel checks.** Module load/unload under `CONFIG_DEBUG_MUTEXES` +8. **Debug-kernel checks.** Module load/unload under `CONFIG_DEBUG_MUTEXES` and a forced `-EPROBE_DEFER` unwind still need a debug kernel build. Both drills cycle what the rail policy avoids: a module unload powers the 40 V rail off (a stepper driver can come out of the power-up unserviceable), and a forced defer needs the 40 V regulator or the SDMA device unbound under the module's probe. This is a bench slot with the rail-cycle gamble accepted, not a quick check. -10. **Wi-Fi SDIO CRC watch.** The uSDHC pads now carry the factory-exact values +9. **Wi-Fi SDIO CRC watch.** The uSDHC pads now carry the factory-exact values and ship in every image. Watch `dmesg | grep -c "sdio .* failed"` across sessions (baseline: 1 event in 49 min of uptime). Effect if one lands mid-job: a 1–2 s sender stall — a cut-quality nuisance, never a safety matter. Only if it still recurs, cap the bus with `max-frequency = <25000000>` on `&usdhc1` (halves Wi-Fi throughput — last resort; the factory ran 50 MHz on these pads). -11. **Release acceptance follow-through.** The campaign is the release gate +10. **Release acceptance follow-through.** The campaign is the release gate and runs as designed: dev image `20260824230512`, 45 of 45 from nothing, 36 of them unattended with the bench actuator in the loop, release authorized (the export is on the board at `/data/forgetest/export/`). @@ -1253,16 +1246,16 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. changes off the offline tests (a gfutilities refactor, not a map). Tools that genuinely need a second host (LAN flood, remote auth probes) stay host-side by design, and the registry marks them so. The first - release is item 12. -12. **Publish.** The first release: `releases/v/acceptance.json` + release is item 11. +11. **Publish.** The first release: `releases/v/acceptance.json` from the authorized export, `scripts/release.sh`, the kas flip and the first GitHub release, per the site (Developers, "Release flow"), once ready to publish. Repoint the core submodule to upstream if the `step_us_min` sizing fix merges. -13. **Update system Phase 5 — recovery refresh.** The remaining phase of +12. **Update system Phase 5 — recovery refresh.** The remaining phase of `docs/UPDATE-SYSTEM.md` (a refreshed recovery image in boot0); Phases 0–4 are done. -14. **Head-IRQ source validation — beam-emission hypothesis (exploratory, not +13. **Head-IRQ source validation — beam-emission hypothesis (exploratory, not gating).** The EV_SW `head` bit (GPIO3_22, factory pad HEAD_IRQ) is the head MCU's attention line — idle LOW with a healthy head, pulsing on head reboot, floating to the SoC pull-up with no head — so the raw level is not a @@ -1278,7 +1271,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. log EV_SW head-bit edges plus `head/beam_detect_digital|_analog` while firing. -15. **Gapless pause and resume in GRBL mode (planned).** A pause leaves a mark +14. **Gapless pause and resume in GRBL mode (planned).** A pause leaves a mark in the cut. With laser mode on, the core stops the beam at the start of the hold (`disable_laser_during_hold`, on by default), so the head travels the whole deceleration dark, and the resume re-accelerates from a standstill at @@ -1312,7 +1305,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. line does to it, and how it composes with the armed window's disarm grace across a long hold. -16. **Head crash and rail-contact detector (planned).** The head +15. **Head crash and rail-contact detector (planned).** The head accelerometer is the motion-liveness probe and nothing more; the factory runs two tiers off the same sensor (a per-axis alert that pauses, a per-axis abort), and its thresholds arrive in every pulse @@ -1324,7 +1317,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. are established. A pause on contact, on the factory's shape, would be the first use. -17. **A sender change while a job runs: discussion.** Today a sender that +16. **A sender change while a job runs: discussion.** Today a sender that disconnects mid-job leaves the motion running to the end of what the controller holds, with the window closed and fire suppressed (the consent belonged to the displaced session), so the job finishes dark @@ -1341,9 +1334,9 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. a hold parks the head over hot material with the assist air on the run profile, and the grace then closes the window in Hold as it does today; running on leaves a clean stop position but wastes the piece. Decide - with the gapless pause and resume item (15), which owns the resume + with the gapless pause and resume item (14), which owns the resume mechanics. -18. **The flow check while the tube is lit.** The arm-time heater check +17. **The flow check while the tube is lit.** The arm-time heater check starts at the session open, so with a prompt press the tube is lit for most of its window, and a lit CW window adds about 1.5 C to the rise (0.5 C at 45 % density) against a 1.6 C margin; on top of that the @@ -1376,7 +1369,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. remains; a scope on the two sensor lines during a cut is the next instrument. It sits inside the ceiling's 2 C hysteresis and the flow check reads means, so it is a measurement item, not a gate item. -19. **Laser power-good: what the line means.** `cnc/laser_pgood` and its +18. **Laser power-good: what the line means.** `cnc/laser_pgood` and its sampled count are defined in the UAPI (active low, one sample every ~3.9 ms), the facts bank records that the sampled count reads 0 through real cutting, and the cooling engine warns @@ -1388,7 +1381,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. scope against `hv_current` through an armed cut, its meaning written into the facts bank and the UAPI, and then either a warning that means something or no warning. -20. **Initial commissioning: measure and set the machine's own numbers +19. **Initial commissioning: measure and set the machine's own numbers methodically.** Every tunable that was measured on the bench machine and shipped as a default varies from machine to machine: the flow check's bands and `cool_flow_rise`, the tube's heat coefficients @@ -1424,7 +1417,7 @@ covers the warm-up hold), the supply temperature window (the service sends the whole ADC range and the factory binds it to nothing; the supply is watched per job instead), the head, lid, interconnect and fused temperature ceilings (no sensor at those locations; the chassis is watched per job), the -head accelerometer thresholds (item 16), the lid IR thresholds (item 3), the +head accelerometer thresholds (item 15), the lid IR thresholds (item 2), the HV current caps (the sampled emission witness covers the idle case, and HV current is ranged per job), the thermal report upload conditions and the -pump flag. Beam detect stays with item 14. +pump flag. Beam detect stays with item 13. diff --git a/docs/CAMPAIGN-LOG.md b/docs/CAMPAIGN-LOG.md index 54516ae..efb8d36 100644 --- a/docs/CAMPAIGN-LOG.md +++ b/docs/CAMPAIGN-LOG.md @@ -4775,6 +4775,42 @@ before the fix was in). The attended set is deferred by decision. The campaign that authorizes a release runs on the image that carries every fix, burned once. +## 2026-08-31: the coolant floor and the warm-up gate, on the bench + +The low-temperature gates landed (forgectrl 5a12f55 and 9d0b757, pinned +in forgefirm f773866) and are bench-proven on the hot-deployed board, +image 20260831141210. `cool_temp_min` is the `coolant_min` gate: under +it the verdict is COLD with a hold, clearing 1 C above the floor +(`gate_floor_trip`, host-tested); a header floor (CMrn) can only raise +it. `cool_temp_start` is the `warm_up` gate: a run session opening under +it holds (WARMUP, fire blocked, phase `warm-up`) with the loop heater at +the flow duty and the fans idle, and releases into a normal run session +with the run fans up and the flow check requested on a fresh history. +The settings cross-check keeps floor under start under ceiling between +gates that are on; both fields are on the panel's Cooling card. + +The first bench run (16:15Z) passed its checks but released 11 s after +the hold: with the pump on, the heater's slug reaches the upstream +sensor within seconds and inflated the instant reading past the gate, +while the bulk warms about half a degree a minute. The release now +judges a one-minute rolling minimum of the upstream reading (between +slugs it falls back to the bulk), the stall warning tracks the same +number, and the catalog test refuses a release under 60 s. The second +run (16:33Z) passed with the right physics: WARMUP held with the heater +at 40 percent (26214 of 65535) and the fans idle, released at 75 s on +the bulk minimum, heater off and run fans up after the release, COLD +tripped with the start gate off, both gates at zero reported off with +the run-start log line, and the settings restored. + +`cooling.floor-and-warm-up` is the catalog case, proving both gates at +room temperature by moving them above the loop; `cool_gate_test` holds +the table rows and the floor hysteresis on the host. The warm-up +holds indefinitely under its gate by design: a loop that stops warming +(the heater plateaus 8 to 9 C over ambient) is named once and keeps +holding, so a shop colder than about 8 C under the gate needs the gate +lowered or the room warmed. The TEC item owns the chill side, with +`cool_temp_min` as its floor. + ## Superseded status notes ### Shared machine services — remaining polish, as listed 2026-08-13 @@ -6309,6 +6345,22 @@ sentence is in the facts bank. Items 2 to 21 are now 1 to 20. margin widening warm; above that only a running tube warms the loop, and the check takes the tube's share off. +### Low-temperature gates and warm-up (item 1), closed 2026-08-31 + +Closed: implemented and bench-proven the same day (the entry above); +the catalog case is `cooling.floor-and-warm-up`. Items 2 to 20 are now +1 to 19. + +1. **Low-temperature gates and warm-up (planned).** Two keys in the Cooling + card: `cool_temp_min` (hard floor, default ~5 °C, a fire gate) and + `cool_temp_start` (warm-up gate, default ~16 °C) — a job starting below the + gate holds in a factory-style warm-up phase with the loop heater on and + releases above it; below the floor nothing fires. Rationale: cold-tube + thermal shock, condensation when the TEC pulls below the dew point, frozen + coolant. Sequencing: warm-up first, flow check after. Measured physics on + this bench: 50 % duty warms the bulk ~0.5–0.8 °C/min and plateaus ~8–9 °C + above ambient — the same unaided limit the factory has. + ## Reference notes ### Head-IRQ source validation — the beam-emission hypothesis