From a3d921b7ee2ee5cd4fa4646814b9aca9285a3cae Mon Sep 17 00:00:00 2001 From: ScottW514 Date: Mon, 31 Aug 2026 12:59:10 -0400 Subject: [PATCH] Retire next-work item 1: the TEC drive is on the bench TEC handling is implemented, host-tested and proven at the GPIO (CAMPAIGN-LOG has the run and the CMet/CMdt correction: readings, not setpoints; the defaults are chosen). BRINGUP: the item closed, items 2 to 19 are now 1 to 18, the five cross-references follow. --- docs/BRINGUP.md | 58 ++++++++++++++++++-------------------------- docs/CAMPAIGN-LOG.md | 54 +++++++++++++++++++++++++++++++++++++++++ 2 files changed, 77 insertions(+), 35 deletions(-) diff --git a/docs/BRINGUP.md b/docs/BRINGUP.md index 2d27b02..51a7846 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 14). A pause is not a cancel: the latch + the deceleration ended (item 13). 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 @@ -1101,19 +1101,7 @@ is committed. Open items only. Anything closed is in `CAMPAIGN-LOG.md`. -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 - while a job runs — TEC on above `cool_tec_on_c`, off below `cool_tec_off_c`, - defaults from the factory setpoints (CMet/CMdt 18134/18364 mdeg — the same - WTub/WTvb raw-754/751 pair that proved the thermistor curve), off at idle — - with `cool_temp_min` as the chill floor, so the TEC can never drive the loop - toward condensation or freeze territory. Whether a given unit has a TEC at - 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. -2. **Fire watch (lid IR) redesign.** The gate stays disabled +1. **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 @@ -1136,11 +1124,11 @@ 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. -3. **Limit-switch homing.** The planned second homing method (`$22` stays 0 +2. **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. -4. **Cameras.** **First light on an 8 MP (OV8856) machine**: the +3. **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 @@ -1155,7 +1143,7 @@ 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. -5. **Cloud mode.** A print is no longer capped by the ring: the client holds +4. **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 @@ -1197,7 +1185,7 @@ 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). -6. **Shared machine services — remaining polish.** None of it blocking: +5. **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 @@ -1213,26 +1201,26 @@ 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. -7. **Physical-evidence negatives still open.** A present head answering I²C +6. **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. -8. **Debug-kernel checks.** Module load/unload under `CONFIG_DEBUG_MUTEXES` +7. **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. -9. **Wi-Fi SDIO CRC watch.** The uSDHC pads now carry the factory-exact values +8. **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). -10. **Release acceptance follow-through.** The campaign is the release gate +9. **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/`). @@ -1246,16 +1234,16 @@ 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 11. -11. **Publish.** The first release: `releases/v/acceptance.json` + release is item 10. +10. **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. -12. **Update system Phase 5 — recovery refresh.** The remaining phase of +11. **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. -13. **Head-IRQ source validation — beam-emission hypothesis (exploratory, not +12. **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 @@ -1271,7 +1259,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`. log EV_SW head-bit edges plus `head/beam_detect_digital|_analog` while firing. -14. **Gapless pause and resume in GRBL mode (planned).** A pause leaves a mark +13. **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 @@ -1305,7 +1293,7 @@ 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. -15. **Head crash and rail-contact detector (planned).** The head +14. **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 @@ -1317,7 +1305,7 @@ 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. -16. **A sender change while a job runs: discussion.** Today a sender that +15. **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 @@ -1334,9 +1322,9 @@ 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 (14), which owns the resume + with the gapless pause and resume item (13), which owns the resume mechanics. -17. **The flow check while the tube is lit.** The arm-time heater check +16. **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 @@ -1369,7 +1357,7 @@ 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. -18. **Laser power-good: what the line means.** `cnc/laser_pgood` and its +17. **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 @@ -1381,7 +1369,7 @@ 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. -19. **Initial commissioning: measure and set the machine's own numbers +18. **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 @@ -1417,7 +1405,7 @@ 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 15), the lid IR thresholds (item 2), the +head accelerometer thresholds (item 14), the lid IR thresholds (item 1), 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 13. +pump flag. Beam detect stays with item 12. diff --git a/docs/CAMPAIGN-LOG.md b/docs/CAMPAIGN-LOG.md index efb8d36..d0a9f46 100644 --- a/docs/CAMPAIGN-LOG.md +++ b/docs/CAMPAIGN-LOG.md @@ -4811,6 +4811,41 @@ 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. +## 2026-08-31: the TEC drive, on the bench + +TEC handling landed (forgectrl 7d8a580, pinned in forgefirm 6edd3e5) and +ran on the hot-deployed board. `thermal/tec_on` has no readback, so the +part's presence is the operator's word: `cool_tec_present` on the +Machine tab, default 0, and the engine never touches the line otherwise, +which also covers retrofits. When present, the engine drives it on a +hysteresis pair over the upstream reading (`cool_tec_on_c` 20 C, +`cool_tec_off_c` 18 C) and only while the fans run - the run, smoke-clear +and thermal phases, or a forced cooldown - because the cooler's heat +sink sits in their airflow. Off at idle, off in the warm-up hold, off +within a degree of the coolant floor; off is immediate, on waits a 30 s +dwell; the state is rewritten after a diagnostic hand-back. The settings +cross-check keeps off under on and above the floor. + +A correction to the item as written: `CMet`/`CMdt` are readings, not +setpoints (attribute word 1, not header-legal; the coolant notes). The +factory's knob is `tec_temp_threshold` (`TCth`), on above it on the +filtered upstream reading; the non-Pro capture parks it at INT32_MAX and +no Pro capture is on hand, so the defaults are chosen, not inherited: +near the observed Pro loop point (18.1 to 18.4 C readings), above the +warm-up gate, above an ordinary room's dew point. + +`cooling.tec-drive` passed on the deployed board (16:55Z): the +cross-checks refused off over on and off under the floor; declared +fitted with the pair moved under the loop, the line went to 1 one +second into an M8 session ("TEC on: coolant 26.4 C over 24.1 C, +airflow up") and back to 0 at the session's end ("TEC off: no +airflow"); declared not fitted, the same session left the line at 0; +the settings were blank before and are blank again. + +Host proof: the two table rows in `cool_gate_test`. This machine is not +teardown-verified to carry the part, so the drive is proven at the GPIO; +the first Pro on the bench proves the cooling itself. + ## Superseded status notes ### Shared machine services — remaining polish, as listed 2026-08-13 @@ -6361,6 +6396,25 @@ the catalog case is `cooling.floor-and-warm-up`. Items 2 to 20 are now 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. +### TEC handling (item 1), closed 2026-08-31 + +Closed: implemented and bench-proven at the GPIO the same day (the +entry above, with the CMet/CMdt correction); the catalog case is +`cooling.tec-drive`. Items 2 to 19 are now 1 to 18. + +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 + while a job runs — TEC on above `cool_tec_on_c`, off below `cool_tec_off_c`, + defaults from the factory setpoints (CMet/CMdt 18134/18364 mdeg — the same + WTub/WTvb raw-754/751 pair that proved the thermistor curve), off at idle — + with `cool_temp_min` as the chill floor, so the TEC can never drive the loop + toward condensation or freeze territory. Whether a given unit has a TEC at + 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. + ## Reference notes ### Head-IRQ source validation — the beam-emission hypothesis