mirror of
https://github.com/openglow-org/forgefirm.git
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ScottW514
8fa10f7b28
Records why the temperature formula changed (and that everything derived from the old one had to be re-derived), the flow characterization data at both heater duties, the false negative that killed the dT-threshold design, and the downstream-rise check that replaced it. Adds flow_characterize.py to the bench kit.
26 lines
3.7 KiB
Markdown
26 lines
3.7 KiB
Markdown
# ForgeFIRM bench tools
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Hardware-verification tools for the ForgeFIRM bench. All run ON the
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target board (dev image, python3 present) unless noted.
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| Tool | Purpose |
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|---|---|
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| `feeder.c` | Spike-step-3 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>`. Passed 100 kHz × 120 s under full load with 0.2 ms worst write latency. Cross-compile with `build-feeder.sh` (WSL). |
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| `bench_phase2.py` | End-of-data protocol bench (audit M2–M5): underrun detection/ack, parked no-replay guard, resume(0), continuous-feed stability, 20× run/underrun cycles. Motion-safe (motors locked, laser latched). 16/16 PASS on 2026-07-26. |
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| `check_pwm.py` | Laser PWM register check (audit M8): reads PWM2 PWMCR/PWMPR via /dev/mem, expects divider 13 × ~127 counts ≈ 40 kHz. |
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| `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). Waveform gate PASSED with it 2026-08-02: 40 kHz stable, duty tracks PWMSAR (6.4 % measured vs 6.3 % commanded at the low end). |
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| `pwm_hold.py` | Holds one PWMSAR value for a scope-measurement window (`pwm_hold.py <sar> <seconds>`), then restores. Same locked-state rule. |
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| `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. All gates PASSED with it 2026-08-02 (2.0000 s pulses exact, both paths). |
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| `fan_test.py` | Fan/coolant bench (Windows-side): snapshots fan PWMs/tachs/temps, drives M8 → cut fans, M9 → cooldown → idle, verifying via tach readbacks. All-green 2026-08-02. |
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| `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. This is what showed the 10 % scheme was unusable (0.04 °C gap) and sized the 30 % check. |
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| `temp_calibrate.py` | Coolant temperature calibration helper (`watch` / `point <measured_C>` / `fit`) — pairs a measured temperature with averaged raw ADC readings and fits the line. Used to sanity-check the factory curve against a thermometer. |
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| `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. |
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| `build-feeder.sh` | Cross-compiles `feeder.c` the same way. |
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| `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 (milestone 2): 700/590 mm/s² accel, 200 mm/s max rate, 28160 Hz travel tick. |
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| `bench_m2.py` | Milestone-2 motion 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. All-green 2026-08-02 at factory-true settings. |
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The build scripts borrow the Yocto cross toolchain + sysroot from the ulfius
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2.7.15 work directory in the WSL build tree; if that path ages out after a
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`bitbake -c clean`, point `TC` at any current target recipe workdir (or build
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a proper SDK with `bitbake meta-toolchain`).
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