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https://github.com/openglow-org/forgefirm.git
synced 2026-09-27 16:51:12 -07:00
baseline: take the fresh-boot reference after the controller applied its config
/mode reports controller=running at the spawn, so the reference dump raced grblHAL's init writes and captured the supervisor's motion-probe values (motor_lock 0, step_freq 10000, y_mode at the module default) instead of the resting state. boot_reference() now waits for the controller's markers (step_freq/motor_lock/y_mode at their fixed values, bounded 20 s, GRBL mode only) plus a 1 s settle before dumping, retakes a saved reference that shows the pre-config state while the boot is still fresh, and marks it otherwise. Tests cover the wait, its timeout, the non-GRBL no-op, the pre-config recognition and the retake.
This commit is contained in:
ScottW514
+7
-1
@@ -1502,7 +1502,13 @@ forgectrl restarts; the fresh-boot dump of this image (uptime 235 s)
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confirmed the fixed values (`motor_lock 8`, `x/y_mode 8`, `x/y_decay 1`,
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`step_freq 28160` - the controller's tick, not the probe's 10000 -
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`ramp_rate 125000`, hold currents 33/5, lamps and button LEDs 0, heater
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and TEC off). Proof: k1-k2 / k3 / fire-abu re-run under the baseline -
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and TEC off). A reference dumped at uptime 30 s on 2026-08-16 showed the
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probe values instead (`motor_lock 0`, `step_freq 10000`, `y_mode 1`): the
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dump raced the controller's init writes - `/mode` reports `running` at the
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spawn, not at the config - so `boot_reference()` now waits for the
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controller's markers (`step_freq`/`motor_lock`/`y_mode` at their fixed
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values, bounded 20 s) before dumping, and retakes a pre-config reference
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while the boot is still fresh. Proof: k1-k2 / k3 / fire-abu re-run under the baseline -
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counters (0,0,0) before and after, the probe verified in 3 s after every
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takeover, no ladder, `post: clean` every time. (2) Two forgectrl items
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for the operator's decision, not changed: the liveness probe should write
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@@ -517,8 +517,10 @@ def dump_all(bl):
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def check_fixed_against(ref, log):
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"""Compare the fixed constants with a fresh-boot dump; log the diffs
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(a differing constant is a fact about this machine, not a leftover)."""
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"""Compare the fixed constants with a fresh-boot dump; log the diffs.
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With the dump taken after the controller applied its config (see
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wait_controller_configured) a differing value is a fact about this
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machine worth a look, not a leftover."""
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diffs = []
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sysfs = ref.get("sysfs") or {}
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for attr, want in FIXED_SYSFS + IDLE_READBACKS:
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@@ -530,6 +532,52 @@ def check_fixed_against(ref, log):
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return diffs
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# The attributes the GRBL controller writes at its own start (its analog
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# config + machine tick): once they read the fixed values the controller
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# has configured the machine. Before that the kernel shows the supervisor's
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# motion-probe leftovers (motor_lock 0, step_freq 10000, y_mode at the
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# module default) - the state /mode already calls "running", because
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# "running" is the spawn, not the config.
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CONFIGURED_MARKERS = [(a, dict(FIXED_SYSFS)[a]) for a in ("cnc/step_freq", "cnc/motor_lock", "cnc/y_mode")]
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CONFIGURED_TIMEOUT_S = 20
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CONFIGURED_SETTLE_S = 1.0
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def reference_preconfig(ref):
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"""True when a saved reference shows the pre-controller state: every
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marker present differs from its fixed value (the probe's step_freq /
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motor_lock and the module's y_mode together), i.e. it was dumped
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before the controller's init writes landed."""
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sysfs = (ref or {}).get("sysfs") or {}
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seen = [(sysfs.get(a), want) for a, want in CONFIGURED_MARKERS if sysfs.get(a) is not None]
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return bool(seen) and all(got != want for got, want in seen)
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def wait_controller_configured(log, mode_body, timeout=CONFIGURED_TIMEOUT_S, sleep=time.sleep):
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"""After the supervisor reports the controller running: block until the
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GRBL controller's init writes have landed (the CONFIGURED_MARKERS read
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their fixed values), then a short settle. Only the GRBL controller
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writes those; in any other mode return at once. Bounded: on timeout
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the caller proceeds and the reference will say so."""
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if not (isinstance(mode_body, dict) and mode_body.get("controller") == "running"
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and (mode_body.get("mode") or "grbl") == "grbl"):
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return True
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t0 = time.time()
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while time.time() - t0 < timeout:
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got = [(a, hw.sysfs_read(a)) for a, _ in CONFIGURED_MARKERS]
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if all(g == want for (a, g), (_, want) in zip(got, CONFIGURED_MARKERS)):
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sleep(CONFIGURED_SETTLE_S)
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log("baseline: controller configured %.1f s after running" % (time.time() - t0))
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return True
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if any(g is None for _, g in got):
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return True # no kernel sysfs (host run): nothing to wait for
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sleep(0.25)
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log("baseline: WARNING - controller did not apply its config within %d s (%s); "
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"the reference may show the supervisor's probe values"
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% (timeout, ", ".join("%s=%s" % (a, hw.sysfs_read(a)) for a, _ in CONFIGURED_MARKERS)))
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return False
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def boot_reference(log, data_dir):
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"""The fresh-boot idle state of this boot: loaded from
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<data_dir>/boot-<boot_id>.json when forgetest already took it, taken
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@@ -539,20 +587,33 @@ def boot_reference(log, data_dir):
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if not bid:
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return None
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path = os.path.join(data_dir, "boot-%s.json" % bid)
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up = uptime_s()
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try:
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with open(path) as f:
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ref = json.load(f)
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log("baseline: fresh-boot reference loaded (%s, taken %s)" % (path, ref.get("ts")))
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return ref
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# A reference dumped before the controller had applied its config
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# (the supervisor's probe values still showing) is retaken while
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# the boot is fresh enough; otherwise it stands, marked.
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if reference_preconfig(ref):
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if up is not None and up <= BOOT_MAX_AGE_S:
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log("baseline: fresh-boot reference %s predates the controller's config; retaking" % path)
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ref = None
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else:
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log("baseline: NOTE fresh-boot reference %s predates the controller's config "
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"(taken %s); the machine's probe values are in it - power-cycle to retake"
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% (path, ref.get("ts")))
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if ref is not None:
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log("baseline: fresh-boot reference loaded (%s, taken %s)" % (path, ref.get("ts")))
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return ref
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except (OSError, ValueError):
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pass
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up = uptime_s()
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if up is None or up > BOOT_MAX_AGE_S:
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log("baseline: no fresh-boot reference for this boot (uptime %s s > %d s); "
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"power-cycle to take one" % (up, BOOT_MAX_AGE_S))
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return None
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bl = Baseline(log)
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bl.wait_settled()
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mode = bl.wait_settled()
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wait_controller_configured(log, mode)
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ref = dump_all(bl)
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ref.update({"ts": now_ts(), "boot_id": bid, "uptime_s": uptime_s()})
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try:
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@@ -1,6 +1,7 @@
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"""The baseline: fixed resting values are restored, preserved values are
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handed back, every deviation is a recorded leftover. Runs against a fake
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sysfs tree; forgectrl is unreachable (service-side checks skip)."""
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import json
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import os
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import shutil
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import struct
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@@ -161,5 +162,86 @@ class BaselineTests(unittest.TestCase):
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self.assertEqual(diffs, ["cnc/step_freq: boot=10000 constant=28160"])
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# -- the reference is taken after the controller applied its config -----
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def _probe_state(self):
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# what the kernel shows between the supervisor's motion probe and
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# the GRBL controller's init writes
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self._attr("cnc/motor_lock", "0")
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self._attr("cnc/step_freq", "10000")
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self._attr("cnc/y_mode", "1")
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def test_wait_configured_returns_once_the_controller_wrote_its_config(self):
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self._probe_state()
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calls = {"n": 0}
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def sleep(_s):
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calls["n"] += 1
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if calls["n"] == 3: # the controller's init writes land
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for attr, val in baseline.CONFIGURED_MARKERS:
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self._attr(attr, val)
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ok = baseline.wait_controller_configured(
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self.lines.append, {"controller": "running", "mode": "grbl", "motion": "verified"},
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timeout=5, sleep=sleep)
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self.assertTrue(ok)
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self.assertTrue(any("controller configured" in l for l in self.lines))
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self.assertGreaterEqual(calls["n"], 4) # 3 polls + the settle
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def test_wait_configured_times_out_and_says_so(self):
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self._probe_state()
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t = {"now": 0.0}
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real_time = baseline.time.time
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baseline.time.time = lambda: t["now"]
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try:
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def sleep(s):
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t["now"] += s
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ok = baseline.wait_controller_configured(
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self.lines.append, {"controller": "running", "mode": "grbl"}, timeout=2, sleep=sleep)
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finally:
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baseline.time.time = real_time
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self.assertFalse(ok)
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self.assertTrue(any("did not apply its config" in l for l in self.lines))
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def test_wait_configured_is_a_noop_outside_grbl_mode(self):
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self._probe_state()
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ok = baseline.wait_controller_configured(
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self.lines.append, {"controller": "running", "mode": "cloud"}, timeout=1,
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sleep=lambda s: self.fail("slept in cloud mode"))
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self.assertTrue(ok)
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ok = baseline.wait_controller_configured(
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self.lines.append, {"controller": "stopped", "mode": "grbl"}, timeout=1,
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sleep=lambda s: self.fail("slept with the controller stopped"))
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self.assertTrue(ok)
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def test_preconfig_reference_is_recognized(self):
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self.assertTrue(baseline.reference_preconfig(
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{"sysfs": {"cnc/motor_lock": "0", "cnc/step_freq": "10000", "cnc/y_mode": "1"}}))
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self.assertFalse(baseline.reference_preconfig(
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{"sysfs": {"cnc/motor_lock": "8", "cnc/step_freq": "28160", "cnc/y_mode": "8"}}))
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# a genuinely different single constant is a machine fact, not pre-config
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self.assertFalse(baseline.reference_preconfig(
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{"sysfs": {"cnc/motor_lock": "8", "cnc/step_freq": "10000", "cnc/y_mode": "8"}}))
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self.assertFalse(baseline.reference_preconfig({"sysfs": {}}))
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def test_stale_preconfig_reference_is_retaken_on_a_fresh_boot(self):
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os.environ["FORGETEST_BOOT_ID"] = "test-boot-2"
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try:
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path = os.path.join(self.tmp, "boot-test-boot-2.json")
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with open(path, "w") as f:
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json.dump({"ts": "old", "sysfs": {"cnc/motor_lock": "0", "cnc/step_freq": "10000",
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"cnc/y_mode": "1"}}, f)
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ref = baseline.boot_reference(self.lines.append, self.tmp)
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up = baseline.uptime_s()
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if up is None or up > baseline.BOOT_MAX_AGE_S:
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# too old to retake: the stale reference stands, marked
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self.assertTrue(any("predates the controller's config" in l for l in self.lines))
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self.assertEqual(ref["ts"], "old")
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else:
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self.assertTrue(any("retaking" in l for l in self.lines))
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self.assertEqual(ref["sysfs"]["cnc/motor_lock"], "8")
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finally:
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os.environ.pop("FORGETEST_BOOT_ID", None)
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if __name__ == "__main__":
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unittest.main()
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