The post-run pass compared the kernel position counters exactly, so a
test that put the head back within a hundredth of a millimeter failed
whenever that distance did not round to the same step.
motion.lid-cancel-home found it on the bench reference. The test cancels
a job with the lid twice and the controller returns the head to the job
start each time, landing 0.038 and 0.037 mm out - the same figures as the
run before it, which passed. This time the two returns left four steps on
X, 0.075 mm at 53.333 steps per mm, and the hand-back called it a
leftover. Twenty-three runs of that test, all passing, on returns of the
same accuracy: whether the residue rounds to zero is chance, not a
property of the machine or of the test.
A difference inside POSITION_DEADBAND_MM (0.1 mm, five steps at x8) on X
and Y is now the quantization rather than a leftover. The head is still
put back, so nothing accumulates over a campaign - only the failure goes.
Z stays exact: the return never moves the lens, so a Z difference is
still a leftover and still unrestorable.
Host-proven: four new unit tests on the boundary (four steps and a moved
Z on either side of it, and an unreadable reading), and the forgetest
suite.
The baseline derives x/y_mode, step_freq, ramp_rate and the configured
markers from the xy_microsteps setting; ramp_rate joins the GRBL
controller's set (the driver writes it; the cloud client runs at the
module's). motion.microstep-modes cycles 8, 16 and 32: the save restarts
the idle controller, the kernel reads the mode with its tick and ramp,
$100/$101 are the mode's and a typed $100 is overwritten, a 40 mm jog at
top speed returns to Idle with the kernel counters over the mode agreeing
with the commanded travel and the accelerometer seeing the head move; the
setting is put back as found.
Bench tools: xy_mode_test.py (the null-sink harness the grblHAL CI runs),
raster_dry.py (a top-speed raster per mode), xy_pattern_accel.py (the
operator's pattern from home with the machine silent and the head
accelerometer listening), arc_tolerance_sweep.py (a $12 ladder on the 9
in circle: the chord rate the protocol loop feeds, about 300 a second, is
the ceiling, not the core), and the xymode and xycircle live drills.
BRINGUP carries the present state and the facts; CAMPAIGN-LOG the dated
record, including the planner-blocks spin (a $398 of 255 or more loops
forever at start, a core bug) and its recovery.
meta-forgefirm: the forgefirm-users init replays the account at boot;
sshd refuses root and empty passwords and runs only while the panel
turns it on; the release image keeps an empty root password for the
console; the console banner; avahi announces forgefirm.local; https in
libmicrohttpd and ulfius; the panel on 80 and 443; the license bundle on
the rootfs; release.sh checks the root policy on the built rootfs.
forgetest: the commission suites (commission, commission_dark,
commission_sheet: 23 cases); the runner turns cloud mode on with the
typed phrase for a test that declares it; the baseline's motor_lock is
0; the log-export test checks the bundle for the camera key; the record
helpers write bytes as given and join the daemon's paths as POSIX. The
stream harness gains rule 24: a hold verdict is held again after a
resume. Bench drills: lens_travel.py and lens_stop_accel.py.
Docs: BRINGUP carries the present state; CAMPAIGN-LOG carries the dated
record.
The first campaign with the bench actuator wired failed
motion.button-hold-resume on the tool, not the machine: the second press
was asked while the first 200 ms pulse was still on, the fixture answered
409, the runner handed the step to an operator who was not in the room,
and the post pass could not jog a controller left in Hold.
- fixture.py: a press waits for the last pulse to end (the fixture's
pulse_ms) plus a 300 ms release, so the controller sees the edge; a
409 for a pulse in progress is waited out against button_pulsing and
retried once.
- runner.py: in an unattended run a fixture refusal ends the test at
once as ERROR naming the refusal; the operator fallback stays for
attended runs.
- baseline.py: a controller in Hold or Door gets a soft reset before the
return jog, position kept.
- tests: the fake fixture refuses a press while one is in progress and
reports button_pulsing; FakeGrbl records ^X and can land a reset in a
chosen state; five new tests.
- docs: ACCEPTANCE.md fixture rules, fixture/README.md tool's side.
No catalog consequence: tool-side change, no covers map moves.
Bench: campaign c-20260824174545-0bdc 25/25 with every action by the
fixture; the hold reset proven by a dry drill.
A cloud client the tool starts for anything but homing comes up under
the /run/gfcloud-nohunt marker: the real client back after the
emulator, a mode the runner switches to or hands back, a controller it
restarts. The service keeps the head position it has. cloud.mode-switch
and cloud.service-protocol keep their hunts, and so does the one real
print: enter_cloud reuses a running session only when that client has
hunted the machine itself (session_hunted: never the emulator's, never
a no-hunt start), otherwise it restarts the client with the hunt, since
a print placed on a head position the service only believes can run the
gantry into a rail. The markers are one start, taken down by the client
that read them first thing; the tool's own removal stays for a start
that never happened. Catalog unchanged; the cloud tests' shared code
moved, so their implementation hashes move with it.
The cloud job tests (lid-abort, lid-during-button-wait, hunt-lid-open,
pause-resume) run in cloud mode and leave the machine there: enter_cloud
reuses a live session (pid-scoped from the client's own websocket state
lines) and switches once from GRBL mode, declaring the change to the
baseline; nothing switches back. Each test judges the log from its own
window, the print by its own "print [id]: finished" line, and waits the
service's follow-up moves out (wait_quiet) before it ends. hunt-lid-open
restarts the cloud client through the supervisor's stop/start lever for
a fresh connect. The former switch-back is what failed the last bench run
of hunt-lid-open (409 machine is not idle: the service was still
re-finding the head after the lid closed).
The baseline is mode-aware: in cloud mode the client owns the GRBL
controller's init values, the lid lamp, and the position counters; the
mode itself is preserved unless the run declared the change
(Context.mode_changed); controller_mode is never handed back as a bare
setting (a bare write left the persisted mode out of step with the live
one). The undeclared-change restore now uses the captured state, which
the post pass never saw before.
The acceptance page gets an "Ignore prerequisites" switch (remembered by
the browser): POST /start {ignore_requires} starts a test whose requires
are unmet, and the run records the unmet prerequisites in its evidence
and log; they stay required for the release. The cloud tests' requires
no longer chain through cloud.mode-switch.
Proof: tests/test_cloud_suite.py replays the four tests on the bench's
own gfcloud excerpts (fixtures/) and the run loop's emitted pause/resume
lines under the real runner Context against a fake forgectrl; baseline
mode tests and the server override test; the whole suite (98) and the
coverage lint pass. Catalog consequence: cloud.* fingerprints move with
the module; the catalog hash moves with the requires.
The lid-cancel tests (motion.lid-cancel-home, laser.lid-cancel-mid-fire)
now check that the KERNEL position counters returned to the job start,
not only grbl's MPos - grbl's drift read 0.000 while the head had not
moved. The baseline reports unplayed bytes queued in the kernel ring
(cnc/position total minus processed) as a leftover and refuses its
return jog while any exist: a run started on top of them replays them
first, which is what put the head into the rail. BRINGUP item 16 records
the bench finding and the stream-engine fix.
/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.
The lid lamp now has a resting policy in forgectrl (lid_lamp_idle,
default 236, asserted at start and at every spawn), so the baseline
expects it there instead of preserving whatever level a boot left, and
forgectrl.settings-bounds proves it: resting at the setting, 256 / -1 /
'bright' refused, a new level applied to the lamp at once, the cleared
key back to the default. Clearing a key goes through the query-string
form (an empty JSON value reads as no setting).
motion.liveness-probe adds the regression the bench needed: with every
axis masked (cnc/motor_lock=15, as a bench tool may leave it) forgectrl
is restarted and its fresh probe must read MOTION OK on the first try -
the probe unmasks the axes itself - and the controller comes up with the
mask cleared. Bench 2026-08-16: MOTION OK at p2p 2047/1341 against the
800 threshold, no ladder.
The baseline's settle no longer counts 'probe verified, spawn pending' as
settled (the post pass ran between the probe's own writes and the
controller's init writes and mis-flagged motor_lock/step_freq): it waits
for the controller to be running, with a bounded allowance for a respawn
backoff.
cloud.mode-switch took the optional connect-time firmware probe file as
the evidence of a live session and failed on a bench where that check is
off; the evidence is now gfcloud's own authenticate/ws-connect lines in
the unified log after the switch, the probe recorded when present. Cloud
mode's connect clears the kernel position counters at the head's start
and its hunt homes the head to the corner: the test tells the runner the
counters were re-zeroed (Context.counters_rezeroed) and jogs the head
back by the counter-measured displacement, and hands the lid lamp back
at the level it found. cloud.gfhome-homing documents that it leaves the
machine homed at the corner.
Baseline: a displaced head is jogged back along its own path by the
kernel-measured X/Y delta through the GRBL controller (bounded 100 mm,
waits out a controller respawn backoff); Z is never touched.
A baseline pass brackets every test and bench tool: before the run the
machine is verified against the fresh-boot idle state and anything off it
is restored; after the run - pass, fail, or abort - it is restored again.
Fixed items are the resting values the boot establishes (module defaults,
forgectrl's start-up writes, the GRBL controller's init writes) and
forgectrl's idle picture (controller running with motion verified, no
diagnostic, camera and cooling engines idle); preserved items (lid lamp
level, position counters, settings map, controller mode) are captured
before and handed back after. Deviations are leftovers: in the run pane,
in the result's evidence, and on the page - attributed to the previous run
when found before, to the run itself when found after.
forgetest takes a fresh-boot reference once per boot (within ten minutes
of boot, after the supervisor settles) as the session's resting lid-lamp
level and the check on the fixed values; the values were confirmed
against a fresh boot of the dev image on the bench (step_freq rests at
28160, the controller's default tick, not the probe's 10000).
Takeover runs capture the controller-owned kernel attributes on entry and
write them back before forgectrl restarts: the bench found the kernel
tests leaving motor_lock=15 behind, which masked the supervisor's
liveness probe - no motion by construction, a false driver-wedge verdict,
the rail-off ladder, and finally motion-fault. The takeover wrapper also
waits for the supervisor to settle on both sides (moved into baseline).
Catalog consequence: none beyond the runner; the tests' own drills are
unchanged.
ScottW514