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https://github.com/openglow-org/forgefirm.git
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ScottW514
58d4d91948
- Controllers stop at K80, before forgectrl at K90: runlevel 0/6 no longer tears down the cooling engine, fire gates, and broker while a controller may still be executing a job. - The grblhal/gfcloud init scripts are real emergency levers: stop routes through the supervisor (POST /controller/stop - a bare pkill was safed and respawned seconds later), start resumes supervision, status exists, and the pkill fallback matches full executable paths instead of truncated names or bare substrings. - slotmigrate: the partition grow gets the same 2048-sector tolerance as the filesystem branch (an exact compare rewrote the MBR at S02 on every boot on disks where the grow cannot land on the last sector), verifies it made progress, and the resize2fs retry is bounded at three attempts with the counter kept on p3 itself. - Installer: archive product/platform are verified after the signature, and a validly signed OLDER release now requires an explicit yes instead of installing as a silent downgrade. All predictable /tmp paths in the installer and ffboot are mktemp now. - release.sh rejects multiple positional versions (the last one used to win silently) and a release without factory-era verification dies unless explicitly bypassed; mkfw.sh refuses to pack when the public key for the post-sign self-check is missing. - forgefirm-logrotate: size-capped rotation (boot + hourly) for the /data logs - a full /data breaks settings, update staging, and the controllers own writes. - Bench build scripts derive every path from their own location or FF_SRC_TOP/FF_BUILD_TOP and log to mktemp files.
ForgeFIRM bench tools
Hardware-verification tools for the ForgeFIRM bench. All run ON the target board (dev image, python3 present) unless noted.
| Tool | Purpose |
|---|---|
feeder.c |
Underrun proof: streams NOP pulse bytes to /dev/glowforge with wall-clock pacing, bounded queue depth, deadman flock, SCHED_FIFO. Usage: feeder <hz> <seconds> <depth_ms>. Proven envelope: 100 kHz × 120 s under full load, 0.2 ms worst write latency. Cross-compile with build-feeder.sh (WSL). |
bench_phase2.py |
End-of-data protocol bench: underrun detection/ack, parked no-replay guard, resume(0), continuous-feed stability, 20× run/underrun cycles. Motion-safe (motors locked, laser latched). |
check_pwm.py |
Laser PWM register check: reads PWM2 PWMCR/PWMPR via /dev/mem, expects divider 13 × ~127 counts ≈ 40 kHz. |
pwm_sweep.py |
LASER_PWM scope test (runs on the board): check = read-only safety readbacks + PWM2 dump; sweep = steps PWMSAR through 50/25/75/6/100 % duty with 4 s holds, then restores. Run only in the locked state (controller stopped, cnc disabled, latch locked). |
pwm_hold.py |
Holds one PWMSAR value for a scope-measurement window (pwm_hold.py <sar> <seconds>), then restores. Same locked-state rule. |
fire_test.py |
FIRE drop-timing scope test (runs on the board): A = latch locked (expects nothing on FIRE/LASER_ON), B = latch unlocked / normal end-of-data, U = true underrun. Duty 0 throughout; refuses to unlock if HV reports good. |
fan_test.py |
Fan/coolant bench (Windows-side): snapshots fan PWMs/tachs/temps, drives M8 → cut fans, M9 → cooldown → idle, verifying via tach readbacks. |
flow_characterize.py |
Coolant flow characterization using the factory temperature curve: baseline → flow → no-flow → recovery, printing the ΔT bands and their separation. Takes the heater duty as an argument (flow_characterize.py 30); aborts if downstream passes 45 °C. |
flow_matrix.py |
The flow-detection design matrix (with flow_sampler.py, which lives on the board at /data/): duty × duration × flow/no-flow, every run from a common cooled baseline, interleaved repeats. One heating trace yields the metric at every candidate duration, so cost and precision come from the same 60 runs. Prints a cost table, a precision table (mean±sd, worst-case margin, d′) and a ranked shortlist. Env: FM_DUTIES, FM_REPEATS, FM_RESULTS. |
flow_sustained.py |
Long-run test of the real re-check cadence via M8: counts verdicts/false faults and tracks whether the loop accumulates heat. |
flow_warm_validate.py |
Runs the real check from a heater-warmed baseline. Note the ceiling: 100 % duty pushes the downstream sensor past 50 °C in 30 s while the bulk barely moves, so warm-loop validation above ~23 °C needs the laser, not the heater. |
flow_recheck_char.py |
Characterizes short in-run re-checks and the differential metric; shows why over-temp cannot see a stopped pump and why passive warming trends are ambiguous. |
temp_calibrate.py |
Coolant temperature spot-check helper (watch / point <measured_C> / fit) — pairs a measured temperature with averaged raw ADC readings and fits a per-machine line to sanity-check the factory curve against a thermometer. |
build-glowforge.sh |
Cross-compiles grblHAL-glowforge (the canonical driver repo, ../../../grblHAL-glowforge) in the forge-yocto WSL distro. Run: wsl -d forge-yocto -- bash <path>/build-glowforge.sh (from PowerShell; Git Bash mangles /mnt/c paths). This is the production controller build. |
build-forgectrl.sh |
Cross-compiles forgectrl (the canonical control-daemon repo, ../../../forgectrl) the same way, borrowing the toolchain from the forgectrl recipe workdir (regenerate with bitbake forgectrl after a clean). |
accel_fast.py |
Direct-I2C sampler for the two head-bus LIS2HH12s (runs on the board; unbinds/rebinds st-accel around the capture, 800 Hz ODR, ~270 Hz per device polled): optional mid-capture jogs via local grblHAL TCP. CSV to /tmp/accel.csv. The head accel is i2c-3 0x1e. |
bump_seek.py |
Accelerometer bump-seek homing prototype (runs on the board): creeps toward a rail in bounded jog segments via grblHAL TCP, learns the moving-noise baseline per segment, detects the contact jolt (~530 Hz sampling, 2-sample confirm), jog-cancels (0x85) and backs off. CSV to /tmp/bump.csv. |
build-feeder.sh |
Cross-compiles feeder.c the same way. |
puls_profile.py |
Decodes factory .puls streams (raw or GF1-headered) into velocity/accel profiles: peak speeds, ramp-slope fits, per-move segments, Z cadence. Runs anywhere (stdlib only). Source of the factory-true grblHAL defaults: 700/590 mm/s² accel, 200 mm/s max rate, 28160 Hz travel tick. |
bench_m2.py |
Motion-quality bench, runs against the board over TCP:23: bounded round-trip jogs (sanity, max-rate, diagonal) + feed-hold/resume mid-move, reporting peak feed, state transitions, and position drift. |
The build scripts borrow the Yocto cross toolchain + sysroot from the ulfius
2.7.15 work directory in the WSL build tree; if that path ages out after a
bitbake -c clean, point TC at any current target recipe workdir (or build
a proper SDK with bitbake meta-toolchain).