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Retire next-work item 1: the fire watch is armed on the bench

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The factory-shaped watch is implemented, host-tested and bench-proven
with the lamp as the flame stand-in (CAMPAIGN-LOG has the run, the
fault-class mapping and the recorded interpretation). BRINGUP: the item
closed, items 2 to 18 are now 1 to 17, the references follow, and the
facts bank reads the armed posture. Pin forgectrl for its doc fix.
This commit is contained in:
ScottW514
2026-08-31 13:48:53 -04:00
parent 678a155dba
commit fe977c0dcc
3 changed files with 100 additions and 50 deletions
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docs/BRINGUP.md
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@@ -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 13). A pause is not a cancel: the latch
the deceleration ended (item 12). 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
@@ -972,10 +972,10 @@ is committed.
full-power cut raises them only +4 to +6 counts and a candle burning on the
bed +3 to +6, with ±3 counts of ambient noise and ~+22 counts of day-to-day
drift. forgectrl's camera engine drives `pic/lid_led` for every lid capture,
and the resting level varies (131, 8 after a reboot, cloud mode sets its own),
so a fixed-count gate fires a phantom FIRE stop on any lamp change.
`cool_fire_ir_delta` therefore ships **0 = watch-only**; each job still logs
baseline and peaks.
and the resting level varies (131, 8 after a reboot, cloud mode sets its own).
The armed fire-watch thresholds sit above the fully lit lamp (alert 275
against a 177 ceiling plus drift), so no lamp change can trip them; each
job still logs baseline and peaks.
- **Emission and HV witnesses**: `cnc/laser_on_sampled` goes to its full 255
count on a commanded fire window and returns to 0 at Idle — the reliable
witness. `pic/hv_current` tracks the cut (0 idle → hundreds/1023 raw while
@@ -1101,34 +1101,11 @@ is committed.
Open items only. Anything closed is in `CAMPAIGN-LOG.md`.
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
lamp-set level, not a fixed count. Even then the signal is weak — a candle
reads like a cut — so the head camera or a real flame sensor is the honest
path to fire detection that means something.
One lead worth a bench hour before building anything. The cloud ships flame
thresholds in every pulse header, and the numbers do not look lamp-naive:
baseline 3 counts on all four channels, alert at 275 and critical at 688 on
the first quartile, 374 and 1022 on the second, with the third and fourth
left at zero. The lamp response (facts bank) puts a fully lit lamp at 161
to 177 counts on every channel and the dark floor at 2, so the factory's
alert sits above the lamp and its baseline matches the floor: the factory
rides out the lamp by choosing thresholds above it rather than by tracking
it, and the watch could be re-armed on fixed numbers after all. Still
unproven: that the header's quartiles map onto the raw channels and share
their units (all four channels behave alike, while the header leaves the
third and fourth quartiles at zero). Confirm against the header the next
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.
2. **Limit-switch homing.** The planned second homing method (`$22` stays 0
1. **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.
3. **Cameras.** **First light on an 8 MP (OV8856) machine**: the
2. **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
@@ -1143,7 +1120,7 @@ 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.
4. **Cloud mode.** A print is no longer capped by the ring: the client holds
3. **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
@@ -1185,7 +1162,7 @@ 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).
5. **Shared machine services — remaining polish.** None of it blocking:
4. **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
@@ -1201,26 +1178,26 @@ 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.
6. **Physical-evidence negatives still open.** A present head answering I²C
5. **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.
7. **Debug-kernel checks.** Module load/unload under `CONFIG_DEBUG_MUTEXES`
6. **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.
8. **Wi-Fi SDIO CRC watch.** The uSDHC pads now carry the factory-exact values
7. **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).
9. **Release acceptance follow-through.** The campaign is the release gate
8. **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/`).
@@ -1234,16 +1211,16 @@ 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 10.
10. **Publish.** The first release: `releases/v<version>/acceptance.json`
release is item 9.
9. **Publish.** The first release: `releases/v<version>/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.
11. **Update system Phase 5 — recovery refresh.** The remaining phase of
10. **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.
12. **Head-IRQ source validation — beam-emission hypothesis (exploratory, not
11. **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
@@ -1259,7 +1236,7 @@ Open items only. Anything closed is in `CAMPAIGN-LOG.md`.
log EV_SW head-bit edges plus `head/beam_detect_digital|_analog` while
firing.
13. **Gapless pause and resume in GRBL mode (planned).** A pause leaves a mark
12. **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
@@ -1293,7 +1270,7 @@ 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.
14. **Head crash and rail-contact detector (planned).** The head
13. **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
@@ -1305,7 +1282,7 @@ 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.
15. **A sender change while a job runs: discussion.** Today a sender that
14. **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
@@ -1322,9 +1299,9 @@ 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 (13), which owns the resume
with the gapless pause and resume item (12), which owns the resume
mechanics.
16. **The flow check while the tube is lit.** The arm-time heater check
15. **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
@@ -1357,7 +1334,7 @@ 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.
17. **Laser power-good: what the line means.** `cnc/laser_pgood` and its
16. **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
@@ -1369,7 +1346,7 @@ 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.
18. **Initial commissioning: measure and set the machine's own numbers
17. **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
@@ -1405,7 +1382,8 @@ 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 14), the lid IR thresholds (item 1), the
head accelerometer thresholds (item 13), the lid IR thresholds (the fire
watch runs on local knobs; the header values stay ignored), 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 12.
pump flag. Beam detect stays with item 11.