The engine acted correctly on the bench (FLAME, hold, fire blocked) but
the test read the forgectrl log tail one second after the trip, before
rsyslog put the line on disk. The two log checks poll the tail for up
to 8 s (_tail_wait) instead of reading it once.
Both tiers of the factory-shaped fire watch, proven with the lid lamp
as the flame stand-in: a q1 alert under the lamp's reading holds the
session as FLAME and does not survive into a fresh one; a q1 critical
latches FIRE with the laser latch locked; all four thresholds at zero
read as the four flame gates off; restored, the watch reads armed. Pin
forgectrl 77a643441c1c0c745a38aabebc68340d26204ce0 (the watch itself).
The TEC policy at room temperature: declared fitted with its thresholds
under the loop, a run session drives the line on and the session's end
returns it to 0; declared not fitted the line stays 0; the cross-checks
refuse off over on and off under the floor. Pin forgectrl
7d8a58035ca7fadebcae47ea9fd53ef2dd810bac (the TEC drive).
The first bench run released in 15 s on the heater slug; the engine now
judges a one-minute rolling minimum, and the test refuses a release
under 60 s. Pin forgectrl 9d0b757f492281d2628da6800db61a1f490fd125.
The catalog case for the two low-side gates: at room temperature the
start gate 1 C above the loop holds the next session in warm-up (heater
on, fans idle, fire blocked) and releases into run at the gate; with the
start gate off, a floor above the loop holds COLD; both at 0 are off and
say so; restored, everything reads as before. Pin forgectrl
5a12f55db6ac632dfc720d9937ca581a7703b7c3 (the gates themselves).
cooling.aa-offset-calibrate gives the tool 540 s (its 420 s stationary
gate plus the six edges) and says so in its steps. Pin forgectrl
7dbb5e1e55a12e6bd1364d920f46c96a3ae2d4ce (the tool settles at the flow
tools' gate before its first edge).
The pin carries the compensation (cool_aa_offset_counts, the
aa-offset-calibrate diagnostic, the panel's Apply); verified with
bitbake -c fetch. The catalog gains cooling.aa-offset-calibrate, which
runs the tool and checks its recommendation and spread.
scripts/bench/offset_probe.py is the differential probe that found the
source: one actuator switched at a time with both sensors at 25 Hz
(survey), the air-assist duty ladder, the gantry jogging under the fan,
and an armed dark dwell. CAMPAIGN-LOG records the four probes and the
result; BRINGUP item 21 names the setting and the calibrate as what
remains on this machine, and item 23 opens the initial commissioning
procedure.
No catalog consequence beyond the new case: a bench tool and records.
A live catalog case: two 30 x 4 mm fills at full power on the press, the
window held open until the engine's flow verdict lands in the forgectrl
log, then M2 and the head brought back. PASS needs a verified line with
the laser's share on it (at least 0.3 C: the window and the fire
overlapped) and the judged rise at least 1 C under cool_flow_rise; an arm
refused by a gate names the gate. Passed on image 20260829190323
(heater rise 11.9 C judged, laser 0.6 off 12.5).
CAMPAIGN-LOG records the run and the day's two air-assist gate holds (a
bench connection, reseated); BRINGUP item 21 names the case.
Catalog: the case covers forgectrl src/cool.* and its neighbors; a new
test, so the manifest's coverage widens rather than moves.
forgectrl pin b27398a: the SoC die joins the watched board temperatures
(/status temps soc_c and the kernel's CPU cooling state soc_throttle,
the Status tab, the per-job range line naming a throttle), a throttle
starting or ending is logged, and the supply sensor stays a raw count by
decision (its heatsink cannot be reached with a thermometer while the
machine runs). forgefirm-app pin e65cfc2 (0.1.16+git): every pulse-header
key without an applier is declared with its reason or counted as
undecided in the job log, and CLOUD.md carries one disposition table for
the whole header.
BRINGUP: the pulse-header envelope item is closed. Its durable content is
in the facts bank ("The factory's envelope, decoded": the mandatory tags,
the empty tach windows, the factory's pause and fail tiers, the
per-sensor units, the unarmed flow controller, and ForgeFIRM's answer
with its catalog proofs) and in the "Deliberately not gated" paragraph,
which names every declared family. Item 19 is now the bench-measured
head crash and rail-contact detector; the fire-watch item holds the
header's lid IR thresholds as its prior. The facts bank also records the
SoC's own thermal guard (85 C passive, 90 C critical, no heatsink on the
factory board) and the board temperatures at idle.
Catalog: cooling.gate-off checks the die field, the unthrottled state at
idle and the widened run-end line (the unit fake mirrors it). COOLING
section 9 and the SERVICES verification status describe the present.
forgectrl pin 368fd0c: the critical-line cross-check binds only while the
ceiling is a gate. cooling.critical-tier pins that a POST setting the
ceiling to its off end is accepted with the default line (the unit fake
mirrors the exemption); CAMPAIGN-LOG records the gate-off failure on dev
image 20260822165832 that found it, and the critical-tier pass.
forgectrl pin 76115fd: the chassis LM75 and the supply sensor ride /status
as temps (degrees and a raw count), the engine ranges them over every run
session into one run-end line, and a critical fault that clears with its
session yields the reason to the standing hold.
Bench: critical_tier_drill.py (a bench tool now, registered as
critical-tier) sets the ceiling, the resume gate and the critical line a
few tenths above the live upstream reading and lets the engine's own
flow-check heater warm the loop through them inside one M8 session;
temp_calibrate.py gains supply-watch, supply-point and supply-fit for the
supply sensor against a thermometer on its heatsink, the fit shown beside
UAPI.md's unverified guess.
Catalog: cooling.gate-off checks the /status temps fields and the run-end
board-temperature line (the unit fake mirrors both, one new failure
case); cooling.critical-tier checks the reason after a faulted session.
Docs: CAMPAIGN-LOG entries for cooling.critical-tier on dev image
20260822154257 and the warm-loop drill (OVERTEMP at 10 s, CRITICAL at
14 s, the fault ending with the session); BRINGUP item 19, the facts bank
(board temperatures at idle), COOLING section 9, the bench README.
forgectrl pin a1875a8: cool_temp_critical_c (default 38 C) is the fail
tier above the coolant ceiling's pause: at or over it in a run session the
verdict is CRITICAL (fire blocked, hold, no resume this job), the fault
ends with the session, the settings API keeps it above the ceiling, and
its top turns the gate off.
Catalog: cooling.critical-tier (auto, 45 tests), driven through the
settings API like cooling.gate-off: a critical line at the ceiling is
refused (and undone should it ever be accepted); with the ceiling, the
resume gate and the critical line all under the coolant's temperature a
session reads CRITICAL rather than OVERTEMP with no resume and the reason
naming the tier and the coolant; after the session the ceiling alone
holds (OVERTEMP); with the critical line at its top the gate is off
(gates_off, the run-start log line) and the ceiling alone pauses;
restored, OK with nothing off. Four unit cases against a scripted engine.
_after_session takes the condition to wait for.
Docs: COOLING (verdict table, section 5, the settings table, the quick
reference), BRINGUP item 19 and the catalog count, the CAMPAIGN-LOG
paragraph for the fan-fault session rule on dev image 20260822145201.
The dated record of dev image 20260822135848: the campaign of every
non-operator, non-live test at 18 of 18 PASS with the measured floors and
the operating-point rule (cooling.fan-gate-trips and the hunt leg of
cloud.mode-switch as recorded), and the unplugged-exhaust-fan drill:
AIRFLOW at the grace plus three ticks with the exhaust dead, the other
fans held, the reason relayed on the Grbl port, the replugged fan ok
inside the next session's grace.
The drill showed the fault riding into idle, where the hold canceled
jogs and would have refused the cloud print that re-proves the fan.
forgectrl pin d51dbdb: the fault ends with its run session, and the next
session judges every fan afresh. cooling.fan-gate-trips checks the
verdict is OK with no hold once the tripped session is over (the unit
fake mirrors it); its covers, and the cooling tests' shared covers, gain
src/coolfmt.* (the tree manifest carries the new files at the bumped pin,
and the lint was right to ask). cloud.mode-switch samples the hunt's gate
rows twice a second: a hunt's run phase is a few seconds long.
Docs: COOLING 3a, BRINGUP item 19, CAMPAIGN-LOG.
forgectrl pin 47e4256: the airflow floors set from the bench measurement
(exhaust 6400, intake 2290, air assist 6000 rpm, purge current 300, grace
15 s) and the operating-point rule: a fan is judged while the laser is
armed, when a job's profile may raise it but never lower it below the run
duty, or whenever it is commanded at the run duty; the service's hunts,
sent with the extraction fans off, are measured and published unjudged.
Catalog: cloud.mode-switch now waits out the connect-time hunt sampling
/cool/status and requires no AIRFLOW, the exhaust row unjudged and the
exhaust actually off; its covers gain forgectrl src/cool.* and
src/airflow.*. cooling.fan-gate-trips uses an 8 s test grace (the
intakes take 7 s to 90 percent and tripped under the old 2 s at the new
floor) and its off leg waits for the row state as well as gates_off.
fan_floor_measure.py names a reply that is not JSON and calls the purge
readings idle and run (the pump is always on).
Docs: COOLING 3a and the settings table, BRINGUP item 19 and a facts-bank
entry with the measured fan speeds, the bench README, and a CAMPAIGN-LOG
entry for the measurement, the two status-document finds, the hunt find
and the hot-deployed bench runs of both tests.
The acceptance catalog gains the test behind forgectrl 5a31d66: an
exhaust floor at the legal maximum must trip AIRFLOW after the grace and
three ticks (hold, fire blocked, no resume, the exhaust gate TRIPPED and
named in the reason); a purge current floor at the ADC rail must trip
the same way; an exhaust floor of zero must read off in gates_off and
trip nothing; restored, the next session must run OK with every fan at
or above its floor. Three host cases against a scripted engine that
models the grace and the readings. The covers map names src/airflow.*.
COOLING.md gains 3a (the airflow gates) and the five settings with their
ranges and bands; SERVICES.md the gate rule, the rows, the AIRFLOW
verdict and fan_gates; SAFETY.md names the floors among the verdict's
inputs; BRINGUP item 19 records the gates as in with provisional floors
and the catalog at 44. Pins: forgectrl 5a31d66, forgefirm-app 81027ff
(0.1.15+git); fetch-verified.
On the bench the test tripped the gate and then failed its off leg: its
M9 and the next M8 were 300 ms apart, the GRBL client reports at 1 Hz
and the engine samples at 1 Hz, so the engine never saw the session
end, the next M8 was not a new run start, and the ceiling was never
re-read. Every M9 now waits for the engine's phase to leave run before
the next M8, and an M8 refuses to open on a session still running.
The failure path restores the settings and then cycles a run session
too: the engine reads settings at run start only, so restoring the file
alone left the bench holding OVERTEMP against the test's 6 C ceiling
until the operator's next job. The scripted engine in the host cases
models the report period, and two cases pin both rules.
The acceptance catalog gains the test behind forgectrl 9e44fdc: the
coolant ceiling set just over its legal minimum must trip OVERTEMP with
a hold and fire blocked at the next run start; set to its top the engine
must skip the gate (verdict OK), report it in gates_off on /status and
/cool/status, and log the run-start line; the original values are
restored, on failure too, and proven restored. Five host cases against a
scripted engine. The cooling covers map now names the files that carry
gate state (gates, settings, status, the panel) and corrects a glob that
matched nothing: the GRBL cooling client is src/glowforge_cooling.c, not
src/gfcool*. The fake forgectrl serves /logs/tail and keeps blank form
values as "clear", which is what the daemon does with them.
Docs: COOLING.md section 8 carries each setting's legal range and
recommended band and a new 8a on turning a gate off; SAFETY.md names
what no setting can reach; ACCEPTANCE.md records that gates are
exercised through the settings API, never GFCOOL_* env overrides;
BRINGUP item 19 records the pattern as landed and the catalog is 43.
forgectrl pin moves to 9e44fdc; fetch-verified.
cooling.fans-quiet-after-motion sat silent for four minutes on the bench
and then failed. Its idle reference was the tachs one second after the
baseline saw the engine go idle, while the previous test's fans were
still coasting at the cooldown level (exhaust 5030 rpm against a true
idle of 0), so it then waited for the fans to come back UP to a level
that was never idle. The cooldown wait printed nothing while it waited.
The reference now needs the engine idle, the idle duty applied to both
fan channels, and three consecutive tach samples that agree; the pass
condition is the idle duty back and the tachs at or below that reference
(lower is quieter, never a fault); M8 must visibly raise the duty; and
every sample of both waits is logged with the phase and the duty, so the
run pane shows the fans coasting down rather than a hang.
Proof: tests/test_cooling_suite.py replays the test under the real
Context against a scripted machine (fake forgectrl, fake sysfs duties,
fake Grbl port): an idle machine passes, the bench case (fans coasting
when the test starts) passes with the reference taken after the coast,
fans left on fail with the reference in the message, and a reference
that never settles fails before anything is jogged. No catalog
consequence beyond the suite module's own hash.
The cloud job tests enter cloud mode and stay there, by design, so a
queue (or an operator) that goes on to a motion test reaches it with
gfcloud as the controller and no grblHAL process to find:
motion.step-timing-under-load failed on exactly that, before it touched
the machine. Nothing in the runner put the machine into the mode a test
needed; the baseline only preserved the mode it found.
A test now declares `mode="grbl"` (or "cloud") in @test. The runner's pre
pass, after the leftovers are handled and before the preserved state is
captured, switches through POST /mode, waits for the supervisor to settle
(controller running, motion verified) and for the Grbl port to answer,
and fails the test with the reason when the mode cannot be established.
Capturing after the switch means the post pass keeps the mode the test
asked for, so the machine changes mode only where the next test asks for
it and never between tests of the same mode. The cloud job tests keep
managing their own entry (enter_cloud also waits for the service
session) and declare nothing.
Tagged: every motion.* test but the mode-agnostic liveness probe, the six
laser.* tests, cooling.fans-quiet-after-motion, cloud.mode-switch and
cloud.gfhome-homing (both start in GRBL mode). controller_pid() now says
what mode forgectrl reports when the process is missing. The page shows
the declared mode as a badge; the Grbl port probe moved to hw.
Proof: tests/test_mode.py (switch_mode against the fake forgectrl,
including a refused switch, a controller that never comes up and a port
that never opens; the runner end to end from cloud mode, from grbl mode,
an undeclared test, and a failed switch). 151 unit tests pass; the
coverage lint is clean. No catalog consequence beyond the suite modules'
own source hashes: the change is to how a test is started, not to what
it proves.
forgectrl answers a started diagnostic with 202 (an async job); the
cooling.flow-verify test asserted 200 and failed on the bench before the
diagnostic ran. No catalog consequence beyond the test's own source
hash.
A stdlib-only daemon on the dev image (HTTP :8090) that runs the acceptance
catalog against the machine from a self-contained page, keeps the append-only
result log under /data/forgetest, and exports the release artifact the gate
reads. Tests declare kind (auto / operator / live), hardware (api / takeover),
coverage globs, prerequisites, and core membership; a test's domain
fingerprint is the hash of the manifest files its globs select plus the
platform and its own implementation, so a PASS stays valid exactly while
nothing it covers changed. Campaign rules: a FAIL ends the campaign, the core
(image health, kernel latch and drills, one live emission witness) is never
inherited, invalidate-all forces a full campaign, no SKIP. Live tests need the
operator acknowledgment and the physical arm press through the controller;
takeover tests stop forgectrl for the duration with a crash-recoverable
marker; the tool never touches the laser latch.
Catalog v1: 24 tests ported from the proven bench drills with their recorded
pass criteria (image, kernel K1-K3 and fire A/B/U, forgectrl API and logs,
motion incl. dead-man, cooling, live laser, camera, update, cloud). The bench
tab lists every scripts/bench tool and runs the board-side ones as
subprocesses (takeover tools wrapped). 44 host unit tests, including the gate
verification fixtures. Installed only by forgefirm-image-dev, with the bench
scripts under /usr/share/forgetest/bench.
ScottW514