forgetest: kernel counters prove the return, and ring residue is a leftover that blocks the jog

The lid-cancel tests (motion.lid-cancel-home, laser.lid-cancel-mid-fire)
now check that the KERNEL position counters returned to the job start,
not only grbl's MPos - grbl's drift read 0.000 while the head had not
moved. The baseline reports unplayed bytes queued in the kernel ring
(cnc/position total minus processed) as a leftover and refuses its
return jog while any exist: a run started on top of them replays them
first, which is what put the head into the rail. BRINGUP item 16 records
the bench finding and the stream-engine fix.

forgetest/forgetest/baseline.py

@@ -109,6 +109,20 @@ def read_position():
         return None
 
 
+def read_ring_residue():
+    """Unplayed bytes queued in the kernel pulse ring: total written minus
+    processed (the cnc/position byte counters), or None when unreadable.
+    Anything but 0 at idle is stale motion that the NEXT run would replay
+    before its own bytes."""
+    try:
+        with open(hw.sysfs_root() + "cnc/position", "rb") as f:
+            raw = f.read(32)
+        processed, total = struct.unpack("<2I", raw[12:20])
+        return int(total) - int(processed)
+    except (OSError, struct.error):
+        return None
+
+
 class Leftover:
     def __init__(self, item, found, expected, action):
         self.item = item
@@ -354,6 +368,10 @@ class Baseline:
             except OSError as e:
                 act = "failed: %s" % e
             left.append(Leftover("laser_latch", "unlocked (interlock 0x%x)" % ilk, "locked", act))
+        residue = read_ring_residue()
+        if residue:
+            left.append(Leftover("pulse ring", "%d unplayed bytes" % residue, "0 (nothing queued)",
+                                 "unrestorable: the next run would replay them first"))
         for attr, want in FIXED_SYSFS:
             got = hw.sysfs_read(attr)
             if got is None or got == want:
@@ -386,6 +404,13 @@ class Baseline:
             return "unrestorable (Z only)" if now[2] != was[2] else "restored"
         if abs(dx) > RETURN_MAX_MM or abs(dy) > RETURN_MAX_MM:
             return "unrestorable: %.1f/%.1f mm exceeds %.0f mm" % (dx, dy, RETURN_MAX_MM)
+        # Never jog on top of stale bytes: a run started now would replay
+        # whatever the ring still holds before the jog, in a direction and
+        # for a distance nobody asked for. Report and leave the head.
+        residue = read_ring_residue()
+        if residue:
+            return ("unrestorable: %d unplayed bytes queued in the kernel ring - a jog would "
+                    "replay them; clear the ring (controller restart) before moving" % residue)
         # a controller may be inside a respawn backoff (seconds): wait for it
         mode = None
         deadline = time.time() + 30

forgetest/forgetest/suite/laser.py

@@ -17,6 +17,7 @@ import time
 from ..catalog import test
 from .. import hw
 from ..runner import Failed
+from .motion import kernel_xy_mm, check_kernel_returned
 
 _LASER_COVERS = [("grblhal-glowforge", "src/**"), ("kernel-module-glowforge", "**"),
                  ("forgectrl", "src/super.c"), ("forgectrl", "src/cool.c"),
@@ -514,6 +515,8 @@ def lid_cancel_mid_fire(ctx):
     with ctx.grbl() as g, LiveJob(ctx, g):
         prepare(ctx, g)
         start = g.status_report()["MPos"]
+        k0 = kernel_xy_mm(ctx)
+        ev["kernel_start"] = k0
         ctx.instruct(ARM_CUE % "40 mm +X and +Y")
         stream(g, ["G91", "G21", "M4", "S400",
                    "G1 X40 F200", "G1 Y40 F200", "G1 X-40 F200", "G1 Y-40 F200",
@@ -576,6 +579,9 @@ def lid_cancel_mid_fire(ctx):
         ctx.log("returned: drift %.3f mm; armed=%s latch_locked=%s button_latch=%s", drift,
                 ev["armed_after"], ev["latch_locked"], ev["button_latch"])
         ctx.check(drift <= 0.05, "head not back at the job start (drift %.3f mm)", drift)
+        # what the MACHINE did: the kernel counters must agree
+        ctx.check(ctx.forgectrl.wait_idle(10, abort=ctx.aborted), "machine not idle after the return")
+        check_kernel_returned(ctx, ev, k0)
         ctx.check(not ev["armed_after"], "armed window still open after the cancel")
         ctx.check(ev["latch_locked"], "kernel latch not locked after the cancel")
         ctx.check(ev["button_latch"] == 1, "hardware button latch not SET after the lid open (%s)", ev["button_latch"])

forgetest/forgetest/suite/motion.py

@@ -559,6 +559,28 @@ _LID_COVERS = _MOTION_COVERS + [("grblhal-glowforge", "src/glowforge_switches.c"
                                 ("grblhal-glowforge", "src/glowforge_laser.c")]
 
 
+def kernel_xy_mm(ctx):
+    """The kernel's own position counters, in mm (forgectrl /status pos):
+    what the machine physically did, independent of what grbl believes."""
+    pos = (ctx.forgectrl.status().get("pos") or {})
+    return float(pos.get("x", 0.0)), float(pos.get("y", 0.0))
+
+
+def check_kernel_returned(ctx, ev, k0, tol_mm=0.1):
+    """After a return-to-start: the kernel counters must be back where the
+    job started too. grbl's own drift can read 0.000 while the head never
+    moved (a run the kernel did not take), which is exactly the failure
+    that must not pass."""
+    k1 = kernel_xy_mm(ctx)
+    kdrift = max(abs(k1[0] - k0[0]), abs(k1[1] - k0[1]))
+    ev["kernel_drift_mm"] = round(kdrift, 3)
+    ctx.log("kernel counters: start (%.2f, %.2f) -> now (%.2f, %.2f), drift %.3f mm",
+            k0[0], k0[1], k1[0], k1[1], kdrift)
+    ctx.check(kdrift <= tol_mm,
+              "the kernel counters did not return to the job start (drift %.3f mm) - "
+              "the return move was counted by grbl but not played by the machine", kdrift)
+
+
 def drain_text(g, seconds):
     """Everything the controller said in the next `seconds`."""
     end = time.time() + seconds
@@ -631,6 +653,8 @@ def lid_cancel_home(ctx):
     with ctx.grbl() as g:
         clean_slate(ctx, g)
         start = g.status_report()["MPos"]
+        k0 = kernel_xy_mm(ctx)
+        ev["kernel_start"] = k0
         ev["start"] = start
         g.command("M5")
         g.command("G91")
@@ -663,6 +687,10 @@ def lid_cancel_home(ctx):
         ev["drift_mm"] = round(drift, 3)
         ctx.log("back at the job start: drift %.3f mm (lid still open)", drift)
         ctx.check(drift <= 0.05, "head not back at the job start (drift %.3f mm)", drift)
+        # what the MACHINE did: the kernel counters must agree (the return
+        # move must have been played, not only planned)
+        machine_idle(ctx, 10)
+        check_kernel_returned(ctx, ev, k0)
         sw = (ctx.forgectrl.status().get("switches") or {})
         ev["lid_at_return"] = sw.get("lid")
         ctx.instruct("Close the lid, then click Done.")

forgetest/tests/test_baseline.py

@@ -119,6 +119,27 @@ class BaselineTests(unittest.TestCase):
         self.assertTrue(items["position"].action.startswith("unrestorable"), items["position"].action)
         self.assertEqual(items["position"].found, [1000, 0, 0])
 
+    def _pos_bytes(self, x, y, z, processed, total):
+        with open(self.sysfs + "cnc/position", "wb") as f:
+            f.write(struct.pack("<3i2I", x, y, z, processed, total))
+
+    def test_ring_residue_is_a_leftover_and_blocks_the_return_jog(self):
+        b = self.bl()
+        cap = b.capture()
+        # the run left 40 unplayed bytes queued in the kernel ring and the
+        # head 1000 counts out: the residue is reported, and the return jog
+        # is refused (it would replay the residue first)
+        self._pos_bytes(1000, 0, 0, 100, 140)
+        left = b.enforce("post", captured=cap)
+        items = {x.item: x for x in left}
+        self.assertIn("pulse ring", items)
+        self.assertEqual(items["pulse ring"].found, "40 unplayed bytes")
+        self.assertIn("unplayed bytes queued", items["position"].action)
+        self.assertEqual(baseline.read_ring_residue(), 40)
+
+    def test_clean_ring_reads_zero_residue(self):
+        self.assertEqual(baseline.read_ring_residue(), 0)
+
     def test_lamp_needs_forgectrl(self):
         # the lamp's idle level comes from forgectrl's settings: without the
         # daemon there is nothing to compare against