mirror of
https://github.com/openglow-org/forgefirm.git
synced 2026-09-28 01:01:12 -07:00
ScottW514
f92147093e
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.
271 lines
9.9 KiB
Python
271 lines
9.9 KiB
Python
#!/usr/bin/env python3
|
|
"""Coolant flow-detection design matrix: heating cost AND detection
|
|
precision across heater duty cycles and check durations.
|
|
|
|
Method. For every (duty, case) the loop is first cooled with the
|
|
cut-profile fans back to a common baseline, so every run starts from the
|
|
same thermal state and the measured rises are comparable. Then the
|
|
heater runs at the given duty while both sensors are sampled at 1 Hz.
|
|
Because a single heating trace contains the rise at every elapsed time,
|
|
one run yields the metric for ALL candidate check durations at once.
|
|
|
|
Two questions answered from the same data:
|
|
1. COST - how much does the check heat the loop? (upstream/bulk rise
|
|
in the flow case, per duty per duration)
|
|
2. PRECISION - how well does it discriminate? (downstream rise, flow
|
|
vs no-flow: separation, worst-case margin, and d' =
|
|
separation / pooled standard deviation)
|
|
|
|
Repeats are interleaved (all conditions in round 1, then round 2, ...)
|
|
so slow ambient drift spreads across conditions instead of confounding
|
|
any single one.
|
|
|
|
Safety: aborts a run if downstream passes ABORT_C; heater off and pump
|
|
on at every exit path. The controller is stopped for the duration so it
|
|
cannot touch the fans or heater, and restarted at the end.
|
|
|
|
Output: incremental JSON to flow_matrix_results.json (so partial runs
|
|
are still usable) and a summary table at the end.
|
|
"""
|
|
import json
|
|
import math
|
|
import os
|
|
import statistics
|
|
import subprocess
|
|
import sys
|
|
import time
|
|
|
|
HOST = '172.16.1.97'
|
|
HERE = os.path.dirname(os.path.abspath(__file__))
|
|
RESULTS = os.path.join(HERE, os.environ.get('FM_RESULTS', 'flow_matrix_results.json'))
|
|
|
|
# Factory B-equation conversion (kernel-module-glowforge/UAPI.md).
|
|
F = 1024.0 * 1.3
|
|
RD, BETA = 10000.0, 3380.0
|
|
RINF = 10000.0 * math.exp(-3380.0 / 298.15)
|
|
|
|
DUTIES = [int(x) for x in os.environ.get('FM_DUTIES', '10,15,20,30,40,50').split(',')]
|
|
REPEATS = int(os.environ.get('FM_REPEATS', '5'))
|
|
RUN_S = 75
|
|
SAMPLE_IV = 1.0
|
|
DURATIONS = [15, 20, 25, 30, 40, 50, 60, 75]
|
|
ABORT_C = 48.0 # below the factory 50 C idle ceiling
|
|
BASE_TOL_C = 0.5 # cooldown target: base + this
|
|
COOL_MAX_S = 300
|
|
|
|
FANS_RUN = ('echo 65535 > /sys/glowforge/thermal/exhaust_pwm; '
|
|
'echo 43278 > /sys/glowforge/thermal/intake_pwm; '
|
|
'echo 204 > /sys/glowforge/head/air_assist_pwm')
|
|
|
|
|
|
def degc(raw):
|
|
raw = float(raw)
|
|
if raw <= 0 or raw >= F:
|
|
return float('nan')
|
|
r = RD / (F / raw - 1.0)
|
|
return BETA / math.log(r / RINF) - 273.15
|
|
|
|
|
|
def board(cmd, timeout=120):
|
|
r = subprocess.run(['wsl', '-d', 'forge-yocto', '--', 'ssh',
|
|
'-o', 'PreferredAuthentications=none',
|
|
'root@' + HOST, cmd],
|
|
capture_output=True, text=True, timeout=timeout)
|
|
return r.stdout
|
|
|
|
|
|
def temps():
|
|
o = board('cat /sys/glowforge/pic/water_temp_1 /sys/glowforge/pic/water_temp_2').split()
|
|
return degc(o[0]), degc(o[1])
|
|
|
|
|
|
def heater(pct):
|
|
board('echo %d > /sys/glowforge/thermal/heater_pwm' % int(65535 * pct / 100))
|
|
|
|
|
|
def pump(on):
|
|
board('echo %d > /sys/glowforge/thermal/water_pump_on' % (1 if on else 0))
|
|
|
|
|
|
def safe_state():
|
|
heater(0)
|
|
pump(True)
|
|
|
|
|
|
def cool_to(base, log):
|
|
"""Cool with cut-profile fans until upstream is back near base."""
|
|
safe_state()
|
|
board(FANS_RUN)
|
|
t0 = time.time()
|
|
while time.time() - t0 < COOL_MAX_S:
|
|
d, u = temps()
|
|
if u <= base + BASE_TOL_C:
|
|
return u, time.time() - t0
|
|
time.sleep(10)
|
|
d, u = temps()
|
|
log(' (cooldown timeout at %.2f C, target %.2f)' % (u, base + BASE_TOL_C))
|
|
return u, time.time() - t0
|
|
|
|
|
|
def run_case(duty, flow, log):
|
|
"""One heating run. Returns dict of rises at each candidate duration."""
|
|
pump(flow)
|
|
time.sleep(3)
|
|
d0, u0 = temps()
|
|
heater(duty)
|
|
raw = board('python3 /data/flow_sampler.py %d %.1f' % (RUN_S, SAMPLE_IV),
|
|
timeout=RUN_S + 60)
|
|
heater(0)
|
|
pump(True)
|
|
|
|
series = []
|
|
for line in raw.strip().splitlines():
|
|
try:
|
|
el, r1, r2 = line.split(',')
|
|
series.append((float(el), degc(r1), degc(r2)))
|
|
except ValueError:
|
|
continue
|
|
|
|
aborted_at = None
|
|
for el, d, u in series:
|
|
if d >= ABORT_C:
|
|
aborted_at = el
|
|
break
|
|
|
|
out = {'duty': duty, 'flow': flow, 'start_down': d0, 'start_up': u0,
|
|
'aborted_at': aborted_at, 'samples': len(series), 'at': {}}
|
|
for target in DURATIONS:
|
|
if aborted_at is not None and target > aborted_at:
|
|
continue
|
|
near = [s for s in series if s[0] <= target]
|
|
if not near:
|
|
continue
|
|
el, d, u = near[-1]
|
|
if abs(el - target) > 4: # no sample close enough
|
|
continue
|
|
out['at'][str(target)] = {'t': el, 'down_rise': d - d0, 'up_rise': u - u0,
|
|
'diff_rise': (d - d0) - (u - u0), 'down_abs': d}
|
|
return out
|
|
|
|
|
|
def summarize(runs, log):
|
|
log('')
|
|
log('=== COST: bulk (upstream) rise during a check, flow case, degrees C')
|
|
log(' duty ' + ''.join('%8s' % ('%ds' % t) for t in DURATIONS))
|
|
for duty in DUTIES:
|
|
cells = []
|
|
for t in DURATIONS:
|
|
vals = [r['at'][str(t)]['up_rise'] for r in runs
|
|
if r['duty'] == duty and r['flow'] and str(t) in r['at']]
|
|
cells.append('%8s' % ('%.2f' % statistics.mean(vals) if vals else '-'))
|
|
log(' %4d%%' % duty + ''.join(cells))
|
|
|
|
log('')
|
|
log('=== PRECISION: downstream-rise discrimination (flow vs no-flow)')
|
|
log(' duty dur flow mean+-sd noflow mean+-sd sep worst d-prime')
|
|
best = []
|
|
for duty in DUTIES:
|
|
for t in DURATIONS:
|
|
fv = [r['at'][str(t)]['down_rise'] for r in runs
|
|
if r['duty'] == duty and r['flow'] and str(t) in r['at']]
|
|
nv = [r['at'][str(t)]['down_rise'] for r in runs
|
|
if r['duty'] == duty and not r['flow'] and str(t) in r['at']]
|
|
if len(fv) < 2 or len(nv) < 2:
|
|
continue
|
|
fm, fsd = statistics.mean(fv), statistics.stdev(fv)
|
|
nm, nsd = statistics.mean(nv), statistics.stdev(nv)
|
|
sep = nm - fm
|
|
worst = min(nv) - max(fv)
|
|
pooled = math.sqrt((fsd ** 2 + nsd ** 2) / 2) or 1e-9
|
|
dprime = sep / pooled
|
|
cost = statistics.mean([r['at'][str(t)]['up_rise'] for r in runs
|
|
if r['duty'] == duty and r['flow'] and str(t) in r['at']])
|
|
best.append((dprime, worst, duty, t, fm, fsd, nm, nsd, sep, cost))
|
|
log(' %4d%% %4ds %6.2f+-%4.2f %6.2f+-%4.2f %5.2f %+5.2f %5.1f'
|
|
% (duty, t, fm, fsd, nm, nsd, sep, worst, dprime))
|
|
|
|
log('')
|
|
log('=== RANKED by d-prime (separation in pooled standard deviations)')
|
|
log(' rank duty dur d-prime worst-margin bulk-cost threshold')
|
|
for i, b in enumerate(sorted(best, reverse=True)[:12], 1):
|
|
dprime, worst, duty, t, fm, fsd, nm, nsd, sep, cost = b
|
|
log(' %4d %4d%% %4ds %7.1f %+11.2f %8.2f %8.2f'
|
|
% (i, duty, t, dprime, worst, cost, (fm + nm) / 2))
|
|
log('')
|
|
log(' (worst-margin = min(no-flow) - max(flow); positive means every')
|
|
log(' observed no-flow run exceeded every observed flow run.')
|
|
log(' bulk-cost = degrees C added to the loop per check.)')
|
|
|
|
|
|
def main():
|
|
t_start = time.time()
|
|
log_path = os.path.join(HERE, 'flow_matrix_log.txt')
|
|
logf = open(log_path, 'a')
|
|
|
|
def log(msg):
|
|
print(msg, flush=True)
|
|
logf.write(msg + '\n')
|
|
logf.flush()
|
|
|
|
log('=== flow matrix started %s' % time.strftime('%Y-%m-%d %H:%M:%S'))
|
|
log('duties=%s repeats=%d run=%ds durations=%s' % (DUTIES, REPEATS, RUN_S, DURATIONS))
|
|
|
|
board('pkill -x grblHAL_glowfor; sleep 1; true')
|
|
log('controller stopped for the experiment')
|
|
board(FANS_RUN)
|
|
safe_state()
|
|
|
|
log('initial settle (180 s with fans)...')
|
|
time.sleep(180)
|
|
d, u = temps()
|
|
base = u
|
|
log('baseline: down=%.2f up=%.2f (target for every run: <= %.2f)'
|
|
% (d, u, base + BASE_TOL_C))
|
|
|
|
runs = []
|
|
if os.path.exists(RESULTS):
|
|
try:
|
|
runs = json.load(open(RESULTS)).get('runs', [])
|
|
log('resuming with %d existing runs' % len(runs))
|
|
except Exception:
|
|
runs = []
|
|
|
|
total = REPEATS * len(DUTIES) * 2
|
|
n = 0
|
|
try:
|
|
for rep in range(REPEATS):
|
|
for duty in DUTIES:
|
|
for flow in (True, False):
|
|
n += 1
|
|
start_t, cool_s = cool_to(base, log)
|
|
r = run_case(duty, flow, log)
|
|
r['rep'] = rep
|
|
r['cooldown_s'] = round(cool_s)
|
|
r['base_at_start'] = start_t
|
|
runs.append(r)
|
|
json.dump({'base': base, 'runs': runs}, open(RESULTS, 'w'), indent=1)
|
|
at30 = r['at'].get('30') or r['at'].get('25') or {}
|
|
log(' [%2d/%2d] rep%d duty%3d%% %-7s start=%.2f down_rise@%s=%s %s'
|
|
% (n, total, rep + 1, duty, 'FLOW' if flow else 'NO-FLOW',
|
|
start_t, '30s' if '30' in r['at'] else '25s',
|
|
('%.2f' % at30['down_rise']) if at30 else 'n/a',
|
|
('ABORT@%.0fs' % r['aborted_at']) if r['aborted_at'] else ''))
|
|
log(' elapsed %.1f h' % ((time.time() - t_start) / 3600))
|
|
except KeyboardInterrupt:
|
|
log('interrupted - summarizing what we have')
|
|
finally:
|
|
safe_state()
|
|
board('echo 0 > /sys/glowforge/thermal/exhaust_pwm; '
|
|
'echo 0 > /sys/glowforge/thermal/intake_pwm')
|
|
|
|
summarize(runs, log)
|
|
|
|
board('cd /data && GFSINK=/dev/glowforge nohup grblHAL_glowforge -p 23 '
|
|
'-e /data/EEPROM-glowforge.DAT > /data/glowforge.log 2>&1 & sleep 2; true')
|
|
log('controller restarted; total elapsed %.2f h' % ((time.time() - t_start) / 3600))
|
|
logf.close()
|
|
|
|
|
|
if __name__ == '__main__':
|
|
sys.exit(main())
|