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forgetest: cooling.floor-and-warm-up; pin forgectrl
The catalog case for the two low-side gates: at room temperature the start gate 1 C above the loop holds the next session in warm-up (heater on, fans idle, fire blocked) and releases into run at the gate; with the start gate off, a floor above the loop holds COLD; both at 0 are off and say so; restored, everything reads as before. Pin forgectrl 5a12f55db6ac632dfc720d9937ca581a7703b7c3 (the gates themselves).
This commit is contained in:
ScottW514
@@ -436,6 +436,160 @@ def gate_off(ctx):
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CRIT_KEYS = ("cool_temp_max", "cool_temp_resume", "cool_temp_critical_c")
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LOW_KEYS = ("cool_temp_min", "cool_temp_start")
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WARMUP_ABOVE_C = 1.0 # the start gate this far above the loop: a few heater minutes
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WARMUP_RELEASE_S = 720 # the flow heater warms the bulk 0.4 to 0.8 C a minute
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HEATER_PWM = "thermal/heater_pwm"
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def _hold_session(ctx, g, fc, until, what, wait):
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"""M8 opens a run session and leaves it open: wait for `until(cool)`
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and return the sample. The caller ends the session."""
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ctx.check(_cool(fc).get("phase") != "run", "%s: a run session is already open", what)
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g.command("M8")
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t0 = time.time()
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c = {}
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while time.time() - t0 < wait:
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ctx.sleep(1)
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c = _cool(fc)
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if until(c):
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break
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ctx.log("%s: verdict %s phase %s fire_ok %s hold %s (after %.0f s)", what, c.get("verdict"),
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c.get("phase"), c.get("fire_ok"), c.get("hold"), time.time() - t0)
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return c
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@test("cooling.floor-and-warm-up", title="The coolant floor blocks fire and the warm-up gate holds a cold start",
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subsystem="cooling", kind="auto", mode="grbl", est_min=9,
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covers=_COOL_COVERS, requires=["kernel.latch-locked-idle", "cooling.gate-off"],
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steps=["Machine idle, coolant at room temperature (10 to 30 C). The test writes the coolant "
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"floor and the warm-up gate and restores them; four M8/M9 sessions, the first with "
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"the loop heater on for a few minutes."],
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description="Both low-side gates, proven at room temperature by moving them above the "
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"loop. Warm-up: the start gate set 1 C above the coolant makes the next run "
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"session hold (WARMUP, hold, fire blocked, phase warm-up) with the loop heater "
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"on and the fans idle; the coolant climbs to the gate and the session releases "
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"into run with the verdict OK, the heater off and the run fans up. Floor: with "
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"the start gate off, a floor set 2 C above the coolant makes the next session "
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"hold COLD with fire blocked. Both at 0 are off, reported in gates_off with the "
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"run-start log line, and the session reads OK. Restored, everything reads as "
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"before.")
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def floor_and_warm_up(ctx):
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fc = ctx.forgectrl
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ev = ctx.evidence
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before = fc.settings()
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orig = {k: before.get(k, "") for k in LOW_KEYS}
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ev["orig"] = orig
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ctx.log("original: %s", orig)
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up = (fc.status().get("coolant") or {}).get("up_c")
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ctx.check(up is not None and 10.0 <= up <= 30.0, "coolant outside the test's range (up_c %s)", up)
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c0 = _cool(fc)
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ctx.check(c0.get("verdict") == "OK" and c0.get("gates_off") == [],
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"engine is not at OK with every gate on before the test: %s", c0)
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gates = before.get("gates") or {}
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g_min, g_start = gates.get("cool_temp_min") or {}, gates.get("cool_temp_start") or {}
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ctx.check(g_min.get("gate") == "coolant_min" and g_min.get("off") == "low",
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"settings reply does not describe cool_temp_min as the coolant_min gate, off at zero: %s", g_min)
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ctx.check(g_start.get("gate") == "warm_up" and g_start.get("off") == "low",
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"settings reply does not describe cool_temp_start as the warm_up gate, off at zero: %s", g_start)
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restored = False
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with ctx.grbl() as grbl:
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ctx.check(grbl.status_report()["state"].startswith("Idle"), "controller is not idle")
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try:
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# Leg 1: the warm-up hold and its release. The gate sits just
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# above the loop, so the heater reaches it in a few minutes.
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gate = round(up + WARMUP_ABOVE_C, 1)
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_set_gates(ctx, fc, {"cool_temp_start": str(gate), "cool_temp_min": orig["cool_temp_min"]})
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c = _hold_session(ctx, grbl, fc, lambda c: c.get("verdict") == "WARMUP", "warm-up hold", VERDICT_WAIT_S)
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ev["warmup_hold"] = c
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heater = hw.sysfs_int(HEATER_PWM)
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duty = _duties()
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ev["warmup_heater_pwm"] = heater
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ev["warmup_duty"] = duty
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ctx.check(c.get("verdict") == "WARMUP", "start gate %s C over coolant %.1f C did not hold the session: %s",
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gate, up, c)
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ctx.check(c.get("fire_ok") is False and c.get("hold") is True, "WARMUP without fire blocked and a hold: %s", c)
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ctx.check(c.get("phase") == "warm-up", "phase %r during the warm-up hold, expected warm-up", c.get("phase"))
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ctx.check(heater is not None and heater > 0, "the loop heater is not on during the warm-up (%s=%s)", HEATER_PWM, heater)
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ctx.check(duty == IDLE_DUTY, "the fans are not idle during the warm-up: %s", duty)
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t0 = time.time()
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c = {}
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while time.time() - t0 < WARMUP_RELEASE_S:
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ctx.checkpoint()
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ctx.sleep(5)
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c = _cool(fc)
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if c.get("verdict") != "WARMUP" or c.get("phase") != "warm-up":
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break
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ev["warmup_release_s"] = round(time.time() - t0)
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ev["warmup_release"] = c
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ctx.log("warm-up release after %s s: verdict %s phase %s up %s (gate %s)", ev["warmup_release_s"],
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c.get("verdict"), c.get("phase"), c.get("up_c"), gate)
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ctx.check(c.get("verdict") == "OK" and c.get("phase") == "run",
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"the warm-up did not release into a run session within %d s: %s", WARMUP_RELEASE_S, c)
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ctx.check(c.get("fire_ok") is True and c.get("hold") is False, "released warm-up without fire_ok and no hold: %s", c)
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ctx.sleep(2)
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heater = hw.sysfs_int(HEATER_PWM)
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duty = _duties()
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ev["run_heater_pwm"] = heater
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ev["run_duty"] = duty
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ctx.check(heater == 0, "the loop heater stayed on after the release (%s=%s)", HEATER_PWM, heater)
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ctx.check(duty != IDLE_DUTY, "the run fans did not come up at the release: %s", duty)
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ctx.check(_tail_has(fc, "warm-up complete: coolant "), "the warm-up release line is missing from the forgectrl log")
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grbl.command("M9")
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_session_ended(ctx, fc, "warm-up")
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# Leg 2: the floor. The start gate off, the floor above the
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# (now warmer) loop.
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up2 = (fc.status().get("coolant") or {}).get("up_c") or up
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floor = round(min(up2 + 2.0, 32.0), 1)
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ctx.check(up2 < floor, "coolant %.1f C leaves no room under the ceiling for a floor above it", up2)
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_set_gates(ctx, fc, {"cool_temp_start": "0", "cool_temp_min": str(floor)})
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c = _run_session(ctx, grbl, fc, lambda c: c.get("verdict") == "COLD", "floor")
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ev["floor"] = c
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ctx.check(c.get("verdict") == "COLD", "floor %s C over coolant %.1f C did not trip: %s", floor, up2, c)
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ctx.check(c.get("fire_ok") is False and c.get("hold") is True, "COLD without fire blocked and a hold: %s", c)
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ctx.check(c.get("gates_off") == ["warm_up"], "gates_off %s with the start gate at 0, expected [warm_up]",
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c.get("gates_off"))
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# Leg 3: both at zero: off, said so, and the session reads OK.
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_set_gates(ctx, fc, {"cool_temp_start": "0", "cool_temp_min": "0"})
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c = _run_session(ctx, grbl, fc, lambda c: c.get("verdict") == "OK" and len(c.get("gates_off") or []) == 2,
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"both off")
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ev["both_off"] = c
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ctx.check(c.get("verdict") == "OK", "gates at 0 did not clear the hold: %s", c)
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ctx.check(sorted(c.get("gates_off") or []) == ["coolant_min", "warm_up"],
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"gates_off %s, expected [coolant_min, warm_up]", c.get("gates_off"))
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ctx.check(_tail_has(fc, "gate coolant_min OFF: cool_temp_min = 0"),
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"the run-start log line for the floor off is missing from the forgectrl log")
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# Restore, and prove the restore at the next run start.
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_set_gates(ctx, fc, orig)
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restored = True
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c = _run_session(ctx, grbl, fc, lambda c: c.get("verdict") == "OK" and not c.get("gates_off"), "restored")
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ev["restored"] = c
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ctx.check(c.get("verdict") == "OK" and c.get("gates_off") == [],
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"engine did not return to OK with no gate off after the restore: %s", c)
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finally:
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if not restored:
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st, body = fc.post("/settings", params=orig)
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ctx.log("restore on failure: POST /settings %s -> %s", orig, st)
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try:
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grbl.command("M9")
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_session_ended(ctx, fc, "restore on failure")
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c = _run_session(ctx, grbl, fc,
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lambda c: c.get("verdict") == "OK" and not c.get("gates_off"),
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"restore on failure")
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ctx.log("restore on failure: engine %s gates_off %s", c.get("verdict"), c.get("gates_off"))
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except Exception as e: # the original failure is the one to report
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ctx.log("restore on failure: run session did not complete (%s)", e)
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after = fc.settings()
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ctx.check(all(after.get(k, "") == orig[k] for k in LOW_KEYS),
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"settings not restored: %s", {k: after.get(k) for k in LOW_KEYS})
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ctx.check(hw.sysfs_int(HEATER_PWM) == 0, "the loop heater is on after the test")
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ctx.check(fc.wait_idle(60, abort=ctx.aborted), "machine did not return to idle")
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@test("cooling.critical-tier", title="The coolant critical line is a fault above the ceiling's pause",
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subsystem="cooling", kind="auto", mode="grbl", est_min=3,
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covers=_COOL_COVERS + [("forgectrl", "src/main.c")], requires=["cooling.gate-off"],
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@@ -2,5 +2,5 @@
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# only SRCREV and PV here - the image manifest leaves *-pin.inc out of the
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# layer content hash because the component entry already identifies the
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# pinned source (forgefirm-image-manifest.bbclass).
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SRCREV = "7dbb5e1e55a12e6bd1364d920f46c96a3ae2d4ce"
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SRCREV = "5a12f55db6ac632dfc720d9937ca581a7703b7c3"
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PV = "0.1.0"
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