Prove the density-only model; record the rasters and the decision

The stream harness keeps the analog rendering as the host-test
conservatism reference (rule 13's mask, the duty ladders) and drops the
M101 switch sessions; rule 18 stays as the derived-floor proof, now
satisfied from boot by the precompute. The lifecycle harness's
state-files scenario asserts the derived floor is in $$ before any arm.
The catalog's laser.power-model-switch goes and laser.power-floor reads
the one floor key with no M-code needed. The mswitch drill goes; the
m4corner drill becomes a single density pass; the dpatch drill returns
to density only.

The CAMPAIGN-LOG records the first rasters (254 and 508 DPI grayscale
wedges: tonality held to ~14 pulse slots per pixel, no dither artifact,
one benign stale-verdict suppression under CPU starvation) and the
decision that ends the analog mode - the strike transient fires a spot
at every beam-on, and the finish comparison found no advantage. BRINGUP,
LIGHTBURN, MOTION and SAFETY describe the density-only present.
This commit is contained in:
ScottW514
2026-08-30 19:41:50 -04:00
parent 67da1ab9bc
commit d612c0099a
10 changed files with 355 additions and 615 deletions
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@@ -6002,6 +6002,20 @@ Built the same evening, host-proven: the controller's published state (the C6 ga
Bench-proven the same day, one armed run of the new `mswitch` drill on the hot-installed cross-built binaries (forgectrl md5 4dc4677a, grblHAL_glowforge 17e5502f, operator-run install): the arm reported "laser armed (density, floor 10 %)", `M5` then `M101 P0` answered ok and reported "laser power model set for this program (analog, floor 16 %)", `$$` read `$35=16` while analog was in force and `$35=10` again after `M2` reported the revert, the armed window carried across the switch with no re-prompt, and the 25 Hz trace showed exactly two discharge segments, the density line pulsed (hv mean 390, max-mean 547) and the analog line steady (mean 567, max-mean 28), dark after the second `M5` (hv max 0). Board cleaned; the hot-deployed binaries stay until the next flash, `/tmp/*.prev` is the rollback.
### M4 into corners under both models, no dropouts, 2026-08-30
Image 20260830200842 (fresh flash; the C6 state files verified live on first boot, the sender field exercised end to end). The `m4corner` drill, one armed run: a corner-heavy pattern (10 mm line, 1.2 mm teeth, 2 mm square, 5 mm reversal, 0.5 mm teeth) at S300 F2000 under M4, cut under density and again under analog via `M101 P0`, passes offset 8 mm (`bench-data/m4corner_20260830.log`). Operator: no unmarked commanded segment on either pass - the derived floors close the analog dead-band dropout, and density cannot reach one. Artifacts as the curves predicted: analog scorches the line start and the square corners (floor 16 plus M4 dwell) and reads ~0.35 of CW at the same commanded 30 % where density reads ~0.12-0.15 and runs faint; the operator accepts density's weakness pending E4 (the per-model S correction). The M101 switch, its report, the M2 revert and two clean discharge windows all held on the shipped image. Items A3 and B4 of the working file close.
### The density time base across feeds: even all the way, 2026-08-30
The `m4feeds` drill on image 20260830200842, one armed run: a 60 mm U per feed (out and return legs 0.6 mm apart, the turn at the far end) at S1000 under M4 density, F1000 and F4000, passes 5 mm apart (`bench-data/m4feeds_S1000_20260830.log`; a first 20 mm retraced attempt was unreadable, `m4feeds_20260830.log`). At cruise the beam read identically at both feeds (thermopile 3202 / 3184, current 961 / 895), as M4 commands; the operator read the material "even all the way" - end to middle and through the turns, both feeds. B3 of the working file closes: M4's velocity scaling holds dose per mm through the accel, the per-tick time base stands, no per-step base is needed.
### The first rasters, and the decision that ends the analog mode, 2026-08-30
B5 on image 20260830200842, the generated grayscale wedge (`bench-data/gray-wedge.png`) from LightBurn in Image/Grayscale mode under density. Run 1, 254 DPI at 3000 mm/min (37 min, one kernel run of 23.5M callbacks): every band distinguishable, the ramp graduated, no pattern beyond the mechanical stepper signature, no dropout; the dark third saturates into char at 100 % layer power (dose, not modulation). One mid-job "fire suppressed: coolant" warning traced to a single stale-verdict beat under CPU starvation (the controller logged "1 late events clamped ... step generation was starved of CPU", min pacing margin 0.0 ms); the flow re-checks passed all job with the tube share off, the ceiling gates on the upstream sensor and never tripped, and nothing shows on the material. Run 2, 508 DPI at 6000 mm/min (39 min, 25.1M callbacks, min margin 13.3 ms, zero clamps, no suppression): tonality held at ~14 pulse slots per pixel - the dither accumulator's cross-pixel averaging recovered the levels - no coarsening, no moire. Witness photos `bench-data/raster_run1_254dpi_20260830.jpg` and `raster_run2_508dpi_20260830.jpg`.
The analog pass (A5) was cancelled by the operator's decision that ends the mode: analog fires a spot at every turn-on, low power included - the strike transient, seen at A1 as the start-of-line spots and at the corner drill as the scorch halo - and the finish comparison had already found no advantage (identical finish on acrylic). Density is the only product model from here; the analog rendering survives only as the host harness's conservatism reference (the mask rule), selectable only in the null-sink build.
## Reference notes
### Head-IRQ source validation — the beam-emission hypothesis