Add the sender-change and RX-overrun harness scenarios and the day's records

laser_lifecycle_test.py gains sender-change-mid-job (a laser-on against a
window closed while the spindle was on must prompt again) and rx-overrun
(a job written past the RX ring is reported, stopped in alarm with the
window closed, and a clean job arms after it). The flowload drill's
verdict parser accepts the engine's laser-share suffix.

BRINGUP: item 20 holds only the owed work; item 21 opens the mid-job
sender-change discussion with the Grbl expectation; item 22 is the flow
check under a lit tube; item 23 is the power-good line's meaning.
CAMPAIGN-LOG records the driver fix and the flow-check reading, both
host-proven.

No catalog consequence: harness scenarios and documentation; no runtime
behavior of the release image changes in this commit.

docs/BRINGUP.md

@@ -1447,13 +1447,64 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`.
     overflowed, and the serial layer drops bytes on a full ring (`serial.c`,
     the overflow flag is set and never read), so the job's M5 and M2 were
     lost, the window stayed open until the sender disconnected, and the
-    following job ran unarmed. Fix, in this order: arm on
+    following job ran unarmed. Owed: the driver fix on an image (the arm
-    `state.on && !laser_ok` (the consent question does not depend on the
+    decided by the window alone, an RX overrun dropping the overrunning
-    previous spindle state); clear the spindle state in `gflaser_disarm`;
+    line whole and aborting the job), one bench drill of each scenario,
-    consume the RX overflow flag (report the error and drop the client, so
+    and the catalog's `covers` widened to `glowforge_laser.c` and
-    a sender that ignores flow control cannot leave a half job behind).
+    `serial.c`.
-    Each part gets a regression test in the null-sink harness with the fix,
+21. **A sender change while a job runs: discussion.** Today a sender that
-    and the catalog's `covers` widens to `glowforge_laser.c` and `serial.c`.
+    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
+    and the material is left with an unfinished cut. This is the stock
+    Grbl and grblHAL expectation for the motion: the controller has no
+    notion of sender presence, executes what its planner and RX ring hold,
+    and then waits; the core's stream code (`stream.c`,
+    `stream_disconnect`) only switches streams, with no hold and no
+    alarm, and senders treat a lost connection as a failed job (LightBurn
+    stops its own side and resumes nothing). ForgeFIRM adds only the
+    disarm on top. The open question is whether the disarm should also
+    feed-hold the job, so a reconnecting sender can press and resume where
+    the cut stopped instead of finding the head at the end of a dark pass:
+    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 (17), which owns the resume
+    mechanics.
+22. **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
+    engine takes its baseline from one sample while the coolant ADC
+    carries a common-mode offset of about 1 C that steps in when the
+    airflow goes to the run profile, steps out when it returns to idle,
+    and toggles between two levels in between. Together they put an
+    ordinary job's check within a few tenths of the limit. Owed, in order:
+    the engine's reading (means for the baseline and the end, the tube's
+    share taken off from the `hv_current` integral, one coefficient per
+    power model) on an image; three `flowload t1` runs to show the
+    engine's rise back in the dark band; a `cooling.*` catalog case with
+    an armed CW load; and if that is not enough, the void-on-emission
+    design with the tube as its own flow tracer.
+    Open question, the offset's source: the timing points at the airflow
+    drive (the step lands one sample after the fans go to run duty, before
+    any HV, and lifts when they go idle, long after the tube is dark), but
+    high-voltage energy coupling into the lines between the sensors and
+    the ADC is the other candidate and a shared path could show both; a
+    scope on the two sensor lines through a session, fans and tube
+    switched separately, decides.
+23. **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
+    `laser power-good degraded during the armed window` whenever fewer
+    than half the samples read low, so the warning fires at every session
+    open and carries no information. Nobody knows what the line reports
+    on this PSU: whether it is the supply's own power-good, an HV-present
+    flag, a polarity we have inverted, or unconnected. Owed: the line on a
+    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.
 
 **Deliberately not gated:** an armed GRBL job after an underrun cuts at the
 stale origin unless homing is required (GRBL mode permits unhomed cutting; the

docs/CAMPAIGN-LOG.md

@@ -4226,6 +4226,88 @@ warned by the engine at every session open, a separate item. The check
 window's own baseline and the tube term are the two candidates the fix
 chooses between; nothing is built yet.
 
+## 2026-08-29: the arm-skip and RX-overrun fix, host-proven
+
+The driver fix for BRINGUP "Next work" item 20 is written in
+grblHAL-glowforge and proven on the host; it is not yet on an image.
+
+**The arm.** `spindleSetState` now arms on `state.on && !laser_ok`: the
+consent question reads the window alone, never the previous spindle state.
+`gflaser_disarm` leaves the spindle-state record alone, since it is the
+core's own view (`spindleGetState`, the `A:S` field, planner sync) and the
+condition no longer depends on it. `tests/laser_arm_test.c` gained case H:
+arm through the press, bump the sender generation, `gflaser_poll` closes
+the window with the record still on, the next laser-on must run the button
+wait again and arm; and case I: a laser-on inside the open window does not
+re-prompt. On the old condition case H fails three checks; on the new one
+the whole harness passes.
+
+**The ring.** In `serial.c`, `rx_byte` on a full ring now drops the
+overrunning line whole: what the ring already holds of it is unwritten back
+to the last newline, the rest is discarded through the line's own newline,
+real-time characters keep passing (they are taken before the ring), and
+the overrun is latched. The driver's realtime hook takes it once, logs it,
+reports `RX overrun: the sender ignored flow control (Bf:); job aborted` to
+the sender and enqueues `^X`, the same stop as the lid cancel: controlled
+deceleration, latch relocked, alarm. `tests/serial_test.c` (new, in CMake
+and CI) pushes 73 lines of 14 bytes, overruns on the 74th with a `?` in
+the middle, and checks: one byte free after 1022, the `?` taken, the
+overrun reported once and only once, every line that fit delivered whole,
+no fragment left behind, the next line after the overrun whole, and the
+same with the overrun landing mid-line; 11 checks pass.
+
+**The null-sink harness** (`laser_lifecycle_test.py`, over TCP, no
+hardware) gained two scenarios and passes 15 of 15: `sender-change-mid-job`
+(M4, a 5 s move, the socket closed at 1 s with the spindle on, reconnect,
+`M3 S100` must prompt and re-arm; the disarm message itself is written while
+no client is connected and is discarded, so the re-arm is the evidence) and
+`rx-overrun` (an armed job, then 120 lines written at once: the overrun
+report arrives, the state goes to Alarm, the window closes, and after `$X`
+a clean job arms again). `laser_stream_test.py` still passes.
+
+**What a sender change means in Grbl terms**, for BRINGUP item 21: neither
+Grbl nor grblHAL knows a sender is present; a lost connection leaves the
+controller executing what its planner and RX ring hold, then waiting; the
+core's `stream_disconnect` only switches streams; senders treat the loss as
+a failed job. ForgeFIRM keeps that for the motion and adds the disarm.
+
+## 2026-08-29: the flow check's reading, host-proven
+
+The cooling engine's flow check (forgectrl `cool.c`) now reads its rise
+from means and takes the tube's share off before the limit; written and
+proven on the host, not yet on an image (BRINGUP item 22).
+
+**The reading.** The baseline is the mean of the settled window the gate
+has just verified (15 samples at 1 Hz), and that history restarts when the
+run airflow profile is applied, so the window is taken entirely under the
+profile and the ADC offset that comes with it sits on both sides of the
+rise; the arm-time check therefore starts about 15 s after the session
+opens instead of one second after. The end reading is the mean of the
+check's last 5 s. The tube's share is one coefficient per power model
+(`cool_laser_heat_cw` 3.06e-5, `cool_laser_heat_density` 2.36e-5 C per
+raw-second of `pic/hv_current`, the numbers of the 2026-08-29 burst runs)
+times the current integral from 15 s before the window to 15 s before its
+end (the heat's lag to the sensor; emission later than that has not
+arrived, so it is not counted, the safe side), bounded at 3 C so no setting
+can subtract the check away. The verdict lines carry the share and the raw
+rise: `coolant flow verified (heater rise 11.8 C, dT 10.7 C; laser 1.5 off
+13.2)`. The two keys are validated in `main.c` (0 to 2e-4) and described in
+`SERVICES.md`; the diagnostics' own flow-verify and flow-calibrate are
+untouched, since they run with the tube dark.
+
+**The proof.** `tests/cool_flow_test.c` (new, in CMake and CI) includes the
+engine source against a fake sysfs tree and a fake clock, with a loop model
+that carries the run-profile offset (-1 C stepping in at the session open
+and toggling 0.6 C), the heater's rise with flow (12 C plateau) or without
+(0.4 C per second) and the tube's heat arriving 15 s after emission. Fifteen
+checks pass: a dark check with flow is verified with no share and its
+baseline is the window's mean; a dark check without flow is SUSPECT; a lit
+CW check with flow is verified with about 1.5 C taken off (raw 13.2, judged
+11.8); a lit check without flow is SUSPECT (20.2 raw, 18.8 judged); an
+absurd coefficient is bounded at 3 C and no flow is still SUSPECT (17.2);
+under the density model the density coefficient applies (1.1 off). The
+`flowload` drill's verdict parser accepts the new suffix.
+
 ## Superseded status notes
 
 ### Shared machine services — remaining polish, as listed 2026-08-13

scripts/bench/laser_lifecycle_test.py

@@ -291,11 +291,85 @@ def test_job_window():
         s.close()
 
 
+def test_sender_change_mid_job():
+    """Rule 3, the hard case: the sender changes while the job is still
+    running with the spindle on, so the core never turns the spindle off
+    between the two sessions. The next laser-on from the new sender must
+    still prompt: the arm decision reads the window, not the spindle-state
+    record (a job whose M5 was lost leaves that record on the same way).
+    M3 after M4 is a state change the core always pushes through
+    set_state, planner-synced, so it lands once the first job's move ends."""
+    s = Session("sender-change-mid-job", disarm_s=60)
+    try:
+        send_line(s.sock, "M4 S100", s.log)
+        send_line(s.sock, "G1 X5 F60", s.log)             # 5 s of motion
+        if not wait_for(s.log, ARMED, 5, s.sock):
+            fail("[sender-change-mid-job] first laser-on did not arm")
+        time.sleep(1.0)
+        s.sock.close()                                     # mid-move, spindle on
+        time.sleep(0.5)
+        # The disarm message is written while no client is connected, and
+        # output with no client is discarded, so the new session cannot
+        # see it; the re-arm below is the evidence the window closed.
+        s.sock = s.connect()
+        before = s.armed_count()
+        s.send_raw("M3 S100")                              # laser-on against a closed window
+        end = time.time() + 15
+        while time.time() < end and s.armed_count() != before + 1:
+            read_avail(s.sock, s.log, 0.2)
+        if s.armed_count() != before + 1:
+            fail("[sender-change-mid-job] a laser-on after a mid-job sender change did not "
+                 "re-arm: the arm read the stale spindle state instead of the window")
+        send_line(s.sock, "M5", s.log)
+        wait_idle(s.sock, s.log)
+        print("PASS [sender-change-mid-job]: a laser-on against a window closed mid-job "
+              "prompted and re-armed")
+    finally:
+        s.close()
+
+
+def test_rx_overrun_aborts():
+    """A sender that writes past the RX ring (Bf: is the contract) loses
+    lines, and a job with lines missing is not the job the sender wrote:
+    the controller reports the overrun, stops the way a ^X stops it
+    (alarm, window closed) and never runs on with a hole in it. A clean
+    job after the reset arms again."""
+    s = Session("rx-overrun", disarm_s=60)
+    try:
+        send_line(s.sock, "M4 S100", s.log)
+        send_line(s.sock, "G1 X1 F600", s.log)
+        if not wait_for(s.log, ARMED, 5, s.sock):
+            fail("[rx-overrun] first laser-on did not arm")
+        job = "".join("G1 X%d F60\n" % (2 + (i % 2)) for i in range(120))   # ~1.3 KB at once
+        s.sock.sendall(job.encode())
+        if not wait_for(s.log, "RX overrun", 10, s.sock):
+            fail("[rx-overrun] the overrun was not reported to the sender")
+        if not s.wait_state("Alarm", 5):
+            fail("[rx-overrun] the overrun did not stop the job (state %s)" % s.state())
+        if s.disarmed_count() < 1:
+            read_avail(s.sock, s.log, 1.0)
+        if s.disarmed_count() < 1:
+            fail("[rx-overrun] the overrun did not close the armed window")
+        send_line(s.sock, "$X", s.log)
+        before = s.armed_count()
+        send_line(s.sock, "M4 S100", s.log)
+        send_line(s.sock, "G1 X0 F600", s.log)
+        end = time.time() + 5
+        while time.time() < end and s.armed_count() != before + 1:
+            read_avail(s.sock, s.log, 0.2)
+        if s.armed_count() != before + 1:
+            fail("[rx-overrun] a clean job after the overrun did not arm")
+        wait_idle(s.sock, s.log)
+        print("PASS [rx-overrun]: the overrun was reported, the job stopped in alarm with "
+              "the window closed, and the next clean job armed")
+    finally:
+        s.close()
+
+
 def test_sender_change():
     """Rule 3: a reconnected sender must re-arm. The grace is set far
     beyond the test horizon so only the sender change can close the
-    window, and the first job ends in M5 so the next M4 is a fresh
+    window; the first job ends in M5 and the next M4 is a fresh laser-on."""
-    laser-on edge (the arm prompt fires on the off->on edge)."""
     s = Session("sender-change", disarm_s=60)
     try:
         send_line(s.sock, "M4 S100", s.log)
@@ -651,6 +725,8 @@ def main():
         fail("controller binary not found at %s" % BIN)
     test_job_window()
     test_sender_change()
+    test_sender_change_mid_job()
+    test_rx_overrun_aborts()
     test_hold_grace()
     test_button_wait_arms()
     test_lid_open_in_wait()

scripts/bench/live_fire_drills.py

@@ -1585,7 +1585,7 @@ FLOWLOAD_PRESS_WAIT_S = 300.0            # the operator's button timeout
 FLOWLOAD_CHANNELS = PCURVE_CHANNELS + (('htr', 'thermal/heater_pwm'),)
 # The engine's own verdict lines, as /cool/status "reason" carries them.
 FLOWLOAD_RISE_RE = re.compile(
-    r'heater rise ([0-9.]+) C(?: \(limit ([0-9.]+), dT ([0-9.]+)\)|, dT ([0-9.]+) C)')
+    r'heater rise ([0-9.]+) C(?: \(limit ([0-9.]+), dT ([0-9.]+)|, dT ([0-9.]+) C)')
 
 
 class CoolPoller: