Retire next-work item 1: the low-temperature gates are on the bench

The coolant floor and the warm-up gate are implemented, host-tested and
bench-proven (CAMPAIGN-LOG has both runs, the heater-slug lesson
included). BRINGUP: item 1 closed, items 2 to 20 are now 1 to 19, the
six cross-references follow, and the facts bank carries the slug fact.
This commit is contained in:
ScottW514
2026-08-31 12:35:37 -04:00
parent f773866f3e
commit 97b10683c2
2 changed files with 79 additions and 34 deletions
+27 -34
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@@ -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, 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. 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 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 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). safing chain re-arms ~216 ms before the first step (facts bank).
- **`lid_policy = hold`** selects stock grblHAL door behavior instead (park in - **`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 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 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 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 - **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 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 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`. Open items only. Anything closed is in `CAMPAIGN-LOG.md`.
1. **Low-temperature gates and warm-up (planned).** Two keys in the Cooling 1. **TEC handling (planned).** `thermal/tec_on` is a bare on/off output with no
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
readback, so presence cannot be detected: it becomes a `tec_present` user readback, so presence cannot be detected: it becomes a `tec_present` user
setting (Machine tab, default off; ForgeFIRM never drives `tec_on` unless setting (Machine tab, default off; ForgeFIRM never drives `tec_on` unless
set), which also covers retrofits. Operation when present: simple hysteresis 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 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 same passive closed-loop cooling), not teardown-verified per unit — another
reason it is a setting. 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 (`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 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 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 cloud job carries. By decision those header thresholds (`IR??`) are the
prior for this redesign and nothing else: the cloud client declares them prior for this redesign and nothing else: the cloud client declares them
ignored, and the watch stays disabled until it is lamp-aware. 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 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 `gfcloud_home_x/y` against a jog to a known reference if the factory corner
offset matters. 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 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 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 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, no register file. No shipped machine applies a per-unit shading table,
so ForgeFIRM owes none. Finally the deferred emulator so ForgeFIRM owes none. Finally the deferred emulator
homing-image smoke, now that the emulator can be pointed at live snapshots. 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 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 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 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 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 (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). 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 - **Diagnostics as engine modes.** The flow tools still drive the thermal
hardware themselves while the engine suspends its writes; the check hardware themselves while the engine suspends its writes; the check
parameters are already shared (`cool.h`), so what remains is folding the 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 `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 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. 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 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: laser off — both need the head connected and a fault injected. Opportunistic:
`STATE_FAULT` recovery via `enable` the next time a DRV8825 fault line `STATE_FAULT` recovery via `enable` the next time a DRV8825 fault line
actually trips. 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 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 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), 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 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 under the module's probe. This is a bench slot with the rail-cycle gamble
accepted, not a quick check. 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 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 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 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 matter. Only if it still recurs, cap the bus with
`max-frequency = <25000000>` on `&usdhc1` (halves Wi-Fi throughput — last `max-frequency = <25000000>` on `&usdhc1` (halves Wi-Fi throughput — last
resort; the factory ran 50 MHz on these pads). 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, and runs as designed: dev image `20260824230512`, 45 of 45 from nothing,
36 of them unattended with the bench actuator in the loop, release 36 of them unattended with the bench actuator in the loop, release
authorized (the export is on the board at `/data/forgetest/export/`). 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). changes off the offline tests (a gfutilities refactor, not a map).
Tools that genuinely need a second host (LAN flood, remote auth probes) 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 stay host-side by design, and the registry marks them so. The first
release is item 12. release is item 11.
12. **Publish.** The first release: `releases/v<version>/acceptance.json` 11. **Publish.** The first release: `releases/v<version>/acceptance.json`
from the authorized export, `scripts/release.sh`, the kas flip and the from the authorized export, `scripts/release.sh`, the kas flip and the
first GitHub release, per the site (Developers, "Release flow"), once first GitHub release, per the site (Developers, "Release flow"), once
ready to publish. Repoint the core submodule to ready to publish. Repoint the core submodule to
upstream if the `step_us_min` sizing fix merges. 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 `docs/UPDATE-SYSTEM.md` (a refreshed recovery image in boot0); Phases 0–4
are done. 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 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, 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 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 log EV_SW head-bit edges plus `head/beam_detect_digital|_analog` while
firing. 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 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 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 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 line does to it, and how it composes with the armed window's disarm grace
across a long hold. 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 accelerometer is the motion-liveness probe and nothing more; the
factory runs two tiers off the same sensor (a per-axis alert that 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 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 are established. A pause on contact, on the factory's shape, would be
the first use. 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 disconnects mid-job leaves the motion running to the end of what the
controller holds, with the window closed and fire suppressed (the controller holds, with the window closed and fire suppressed (the
consent belonged to the displaced session), so the job finishes dark 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 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; 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 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. 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 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 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 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 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 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. 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 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 ~3.9 ms), the facts bank records that the sampled count reads 0 through
real cutting, and the cooling engine warns 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 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 into the facts bank and the UAPI, and then either a warning that means
something or no warning. 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 methodically.** Every tunable that was measured on the bench machine
and shipped as a default varies from machine to machine: the flow and shipped as a default varies from machine to machine: the flow
check's bands and `cool_flow_rise`, the tube's heat coefficients 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 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 watched per job instead), the head, lid, interconnect and fused temperature
ceilings (no sensor at those locations; the chassis is watched per job), the 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 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 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.
+52
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@@ -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 campaign that authorizes a release runs on the image that carries every
fix, burned once. 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 ## Superseded status notes
### Shared machine services — remaining polish, as listed 2026-08-13 ### 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, margin widening warm; above that only a running tube warms the loop,
and the check takes the tube's share off. 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 ## Reference notes
### Head-IRQ source validation — the beam-emission hypothesis ### Head-IRQ source validation — the beam-emission hypothesis