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https://github.com/openglow-org/forgefirm.git
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Flow-detection experimental record and bench tooling
Adds the design matrix and its supporting tools, and records in BRINGUP what the 60-run matrix overturned: sub-40-percent duty mimics flow (three of five dead-pump trials looked healthier than a working pump), the operating point and threshold now rest on 25 pooled observations, periodic re-checks are thermally free with the fans running, and the settle gate closes a bench-proven miss. Also records what is NOT yet validated - warm-loop baselines and behaviour under laser heating - as first-light commissioning items.
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ScottW514
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#!/usr/bin/env python3
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"""Validate the flow check at a WARM loop baseline - the condition a
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real job actually presents.
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Every design-matrix run started near ambient (21-23 C). During a cut the
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loop sits warmer, where heat loss to ambient is larger, which shrinks
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the measured rise in BOTH the flow and no-flow cases and could compress
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the margin the threshold depends on. This warms the loop with its own
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heater (which plateaus near 28-29 C - the most it can reach unaided),
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then runs the real check at 40% / 50 s with the cut-profile fans, and
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alternates flow / no-flow so both cases see the same conditions.
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Usage: flow_warm_validate.py [cycles_per_case] (default 3)
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"""
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import json
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import math
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import os
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import statistics
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import subprocess
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import sys
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import time
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HOST = '172.16.1.97'
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HERE = os.path.dirname(os.path.abspath(__file__))
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RESULTS = os.path.join(HERE, 'flow_warm_results.json')
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F = 1024.0 * 1.3
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RD, BETA = 10000.0, 3380.0
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RINF = 10000.0 * math.exp(-3380.0 / 298.15)
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DUTY = 40
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CHECK_S = 50
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THRESHOLD = 13.7
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WARM_TARGET_C = 25.5 # what a ~19-20 C room permits at 50% duty
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WARM_MAX_S = 780
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ABORT_C = 48.0
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FANS_RUN = ('echo 65535 > /sys/glowforge/thermal/exhaust_pwm; '
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'echo 43278 > /sys/glowforge/thermal/intake_pwm')
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FANS_OFF = ('echo 0 > /sys/glowforge/thermal/exhaust_pwm; '
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'echo 0 > /sys/glowforge/thermal/intake_pwm')
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def degc(raw):
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raw = float(raw)
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if raw <= 1.0 or raw >= F:
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return float('nan')
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r = RD / (F / raw - 1.0)
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return BETA / math.log(r / RINF) - 273.15
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def board(cmd, timeout=120):
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r = subprocess.run(['wsl', '-d', 'forge-yocto', '--', 'ssh',
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'-o', 'PreferredAuthentications=none',
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'root@' + HOST, cmd],
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capture_output=True, text=True, timeout=timeout)
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return r.stdout
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_last_good = (22.0, 22.0)
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def temps():
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"""Sanity-guarded read. A single glitched sysfs value used to map to
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~109 C and trip the safety abort, silently ending the warm phase
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after one iteration - which wasted two whole validation runs."""
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global _last_good
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o = board('cat /sys/glowforge/pic/water_temp_1 /sys/glowforge/pic/water_temp_2').split()
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if len(o) != 2:
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return _last_good
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d, u = degc(o[0]), degc(o[1])
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if any(x != x or x < 5.0 or x > 60.0 for x in (d, u)):
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return _last_good
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_last_good = (d, u)
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return d, u
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def heater(pct):
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board('echo %d > /sys/glowforge/thermal/heater_pwm' % int(65535 * pct / 100))
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def pump(on):
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board('echo %d > /sys/glowforge/thermal/water_pump_on' % (1 if on else 0))
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def warm_to(target, log):
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"""Warm with the loop heater, pump circulating, fans off."""
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pump(True)
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board(FANS_OFF)
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# 50% is the practical ceiling: the downstream sensor sits AT the
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# heater element, so 100% drives it past 50 C within 30 s while the
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# bulk has barely moved. At 50% it plateaus near 41 C, leaving the
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# bulk free to climb for as long as we let it.
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heater(50)
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t0 = time.time()
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# Plateau detection compares against the reading two minutes back:
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# with the pump circulating, the bulk climbs only ~0.5-0.8 C/min, so
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# a per-sample threshold mistakes normal warming for a plateau (it
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# did exactly that on the first attempt and the whole run executed
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# at ambient).
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hist = []
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while time.time() - t0 < WARM_MAX_S:
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d, u = temps()
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el = (time.time() - t0) / 60
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if u >= target:
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log(' warm target reached: up=%.2f at %.1f min' % (u, el))
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break
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if d >= ABORT_C:
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log(' warm abort: downstream %.2f at %.1f min' % (d, el))
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break
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hist.append(u)
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if len(hist) % 4 == 0:
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log(' warming: %.1f min down=%.2f up=%.2f' % (el, d, u))
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if len(hist) > 8 and u - hist[-9] < 0.3:
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log(' (warming plateaued at %.2f C after %.1f min)' % (u, el))
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break
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time.sleep(15)
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heater(0)
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pump(True)
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time.sleep(45) # mix so the bulk is uniform before measuring
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d, u = temps()
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log(' warmed to down=%.2f up=%.2f in %.1f min' % (d, u, (time.time() - t0) / 60))
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return u
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def check(flow, log):
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"""The real check: fans at cut profile, 40% heater, 50 s."""
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board(FANS_RUN)
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pump(flow)
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time.sleep(3)
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d0, u0 = temps()
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heater(DUTY)
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raw = board('python3 /data/flow_sampler.py %d 1.0' % CHECK_S, timeout=CHECK_S + 60)
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heater(0)
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pump(True)
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series = []
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for line in raw.strip().splitlines():
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try:
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el, r1, r2 = line.split(',')
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series.append((float(el), degc(r1), degc(r2)))
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except ValueError:
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continue
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if not series:
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return None
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el, d, u = series[-1]
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return {'flow': flow, 'base_up': u0, 'base_down': d0, 'down_rise': d - d0,
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'up_rise': u - u0, 'peak_down': max(s[1] for s in series), 't': el}
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def main():
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cycles = int(sys.argv[1]) if len(sys.argv) > 1 else 3
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logf = open(os.path.join(HERE, 'flow_warm_log.txt'), 'a')
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def log(msg):
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print(msg, flush=True)
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logf.write(msg + '\n')
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logf.flush()
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log('=== warm-baseline validation %s duty=%d%% window=%ds threshold=%.1f'
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% (time.strftime('%Y-%m-%d %H:%M:%S'), DUTY, CHECK_S, THRESHOLD))
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board('pkill -x grblHAL_glowfor; sleep 1; true')
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runs = []
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try:
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for c in range(cycles):
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for flow in (True, False):
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log(' cycle %d/%d %s' % (c + 1, cycles, 'FLOW' if flow else 'NO-FLOW'))
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warm_to(WARM_TARGET_C, log)
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r = check(flow, log)
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if r:
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r['cycle'] = c
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runs.append(r)
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verdict = 'FAULT' if r['down_rise'] > THRESHOLD else 'ok'
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correct = (verdict == 'FAULT') == (not flow)
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log(' base_up=%.2f down_rise=%.2f -> %-5s %s (peak down %.1f C)'
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% (r['base_up'], r['down_rise'], verdict,
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'CORRECT' if correct else '*** WRONG ***', r['peak_down']))
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json.dump(runs, open(RESULTS, 'w'), indent=1)
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finally:
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heater(0)
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pump(True)
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board(FANS_OFF)
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fv = [r['down_rise'] for r in runs if r['flow']]
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nv = [r['down_rise'] for r in runs if not r['flow']]
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log('')
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log('=== warm-baseline results (baselines %.1f - %.1f C)'
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% (min(r['base_up'] for r in runs), max(r['base_up'] for r in runs)))
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if len(fv) >= 2 and len(nv) >= 2:
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log(' flow n=%d mean %.2f sd %.2f max %.2f' % (len(fv), statistics.mean(fv), statistics.stdev(fv), max(fv)))
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log(' no-flow n=%d mean %.2f sd %.2f min %.2f' % (len(nv), statistics.mean(nv), statistics.stdev(nv), min(nv)))
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log(' worst-case margin: %+.2f C threshold %.1f sits %+.2f above flow max, %+.2f below no-flow min'
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% (min(nv) - max(fv), THRESHOLD, THRESHOLD - max(fv), min(nv) - THRESHOLD))
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wrong = [r for r in runs if ((r['down_rise'] > THRESHOLD) != (not r['flow']))]
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log(' misclassified: %d of %d' % (len(wrong), len(runs)))
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board('cd /data && GFSINK=/dev/glowforge nohup grblHAL_glowforge -p 23 '
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'-e /data/EEPROM-glowforge.DAT > /data/glowforge.log 2>&1 & sleep 2; true')
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log('controller restarted')
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logf.close()
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if __name__ == '__main__':
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sys.exit(main())
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