mirror of
https://github.com/openglow-org/forgefirm.git
synced 2026-09-27 16:51:12 -07:00
ScottW514
c1591e4f69
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.
526 lines
24 KiB
Python
526 lines
24 KiB
Python
"""cooling.fans-quiet-after-motion and cooling.gate-off replayed host-side
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under the real runner Context against a scripted machine: a fake
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forgectrl (/status fans, /cool/status phase and verdict, /settings with
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the gates table, /logs/tail), a fake kernel sysfs (the fan duties), and
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a fake Grbl port that answers '?' and every command.
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The bench case that motivated this: the test started one second after
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the engine of a previous test went idle, took the tachs still coasting
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at the cooldown level as its idle reference, and then waited for the
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fans to come back UP to it. The idle reference now needs the engine
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idle, the idle duty applied, and tachs that have stopped changing; the
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pass condition is at-or-below that level, and every sample is logged.
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"""
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import os
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import shutil
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import socket
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import tempfile
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import threading
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import time
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import unittest
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import helpers
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from forgetest.runner import Context, Failed, Run
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from forgetest.suite import cooling
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class FakeGrbl:
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"""Answers '?' with an Idle report and every line with ok."""
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def __init__(self):
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self.sock = socket.socket()
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self.sock.bind(("127.0.0.1", 0))
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self.sock.listen(2)
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os.environ["GRBL_HOST"] = "127.0.0.1"
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os.environ["GRBL_PORT"] = str(self.sock.getsockname()[1])
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self.commands = []
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self.on_command = None
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self._stop = False
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threading.Thread(target=self._serve, daemon=True).start()
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def _serve(self):
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self.sock.settimeout(0.2)
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while not self._stop:
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try:
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c, _ = self.sock.accept()
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except OSError:
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continue
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threading.Thread(target=self._client, args=(c,), daemon=True).start()
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def _client(self, c):
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c.settimeout(0.1)
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buf = b""
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c.sendall(b"\r\nGrbl 1.1f ['$' for help]\r\n")
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while not self._stop:
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try:
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d = c.recv(4096)
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except socket.timeout:
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continue
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except OSError:
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break
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if not d:
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break
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for ch in d:
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if ch == 0x3F: # '?'
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c.sendall(b"<Idle|MPos:0.000,0.000,0.000|FS:0,0>\r\n")
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elif ch in (0x18, 0x85):
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pass
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else:
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buf += bytes([ch])
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while b"\n" in buf:
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line, buf = buf.split(b"\n", 1)
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line = line.decode().strip()
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if line:
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self.commands.append(line)
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if self.on_command:
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self.on_command(line)
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c.sendall(b"ok\r\n")
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c.close()
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def close(self):
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self._stop = True
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self.sock.close()
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for k in ("GRBL_HOST", "GRBL_PORT"):
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os.environ.pop(k, None)
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class FansQuietTests(unittest.TestCase):
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def setUp(self):
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self.tmp = tempfile.mkdtemp(prefix="forgetest-cool-")
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self.sysfs = os.path.join(self.tmp, "sysfs") + os.sep
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os.makedirs(self.sysfs + "thermal")
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os.environ["GF_SYSFS_ROOT"] = self.sysfs
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self.fc = helpers.FakeForgectrl().start()
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self.grbl = FakeGrbl()
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self.saved = (cooling.SAMPLE_S, cooling.IDLE_REF_TIMEOUT_S, cooling.COOLDOWN_TIMEOUT_S)
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cooling.SAMPLE_S = 0.1
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cooling.IDLE_REF_TIMEOUT_S = 3
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cooling.COOLDOWN_TIMEOUT_S = 4
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self.fc.state["cool"] = {"phase": "idle", "armed": False, "hold": False}
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self.duty(0, 0)
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self.fans(0, 736, 733)
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def tearDown(self):
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cooling.SAMPLE_S, cooling.IDLE_REF_TIMEOUT_S, cooling.COOLDOWN_TIMEOUT_S = self.saved
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self.grbl.close()
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self.fc.stop()
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os.environ.pop("GF_SYSFS_ROOT", None)
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shutil.rmtree(self.tmp, ignore_errors=True)
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# -- the machine -------------------------------------------------------
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def duty(self, exhaust, intake):
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for attr, v in (("thermal/exhaust_pwm", exhaust), ("thermal/intake_pwm", intake)):
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with open(self.sysfs + attr, "w") as f:
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f.write(str(v))
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def fans(self, exhaust, i1, i2, air=2080):
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self.fc.state["status"] = dict(self.fc.state["status"],
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fans={"air_assist": air, "exhaust": exhaust, "intake_1": i1, "intake_2": i2})
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def run_engine(self):
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"""M8 -> run profile; M9 -> smoke phase, then idle duty, then the
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tachs coast down (a few samples of spin-down), like forgectrl's
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engine on the bench."""
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def on_command(line):
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if line == "M8":
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self.duty(65535, 43278)
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self.fc.state["cool"]["phase"] = "run"
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self.fans(6753, 3212, 3328, air=10997)
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elif line == "M9":
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def cooldown():
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self.fc.state["cool"]["phase"] = "smoke"
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time.sleep(0.3)
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self.fc.state["cool"]["phase"] = "idle"
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self.duty(0, 0)
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for ex, i1 in ((5030, 3319), (3100, 2200), (1200, 1300), (0, 740)):
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self.fans(ex, i1, i1 + 5)
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time.sleep(0.25)
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threading.Thread(target=cooldown, daemon=True).start()
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self.grbl.on_command = on_command
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def run_test(self):
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run = Run("test", "cooling.fans-quiet-after-motion", "t")
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ctx = Context(run, None, helpers.make_test("cooling.fans-quiet-after-motion", []))
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cooling.fans_quiet(ctx)
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return run
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# -- cases ------------------------------------------------------------------
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def test_idle_machine_passes_and_logs_every_sample(self):
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self.run_engine()
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run = self.run_test()
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self.assertEqual(run.evidence["before"]["exhaust"], 0)
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self.assertIsNotNone(run.evidence["settle_s"])
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self.assertEqual(run.evidence["duty_after"], cooling.IDLE_DUTY)
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self.assertIn("M8", self.grbl.commands)
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self.assertIn("M9", self.grbl.commands)
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cooldown_lines = [ln for ln in run.lines if "cooldown +" in ln]
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self.assertGreaterEqual(len(cooldown_lines), 2, run.lines)
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def test_a_spin_down_in_progress_is_not_taken_as_the_idle_reference(self):
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"""The bench case: the previous test's fans are still coasting when
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this one starts. The reference waits for them to settle, and the
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run passes instead of waiting for the fans to come back up."""
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self.run_engine()
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self.fans(5030, 3319, 3377) # coasting, engine already idle, duty 0
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def coast():
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for ex, i1 in ((3900, 2600), (2500, 1700), (1100, 1000), (0, 736), (0, 736)):
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time.sleep(0.12)
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self.fans(ex, i1, i1 + 5)
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threading.Thread(target=coast, daemon=True).start()
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run = self.run_test()
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self.assertEqual(run.evidence["before"]["exhaust"], 0, run.evidence["before"])
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self.assertGreater(run.evidence["idle_ref_s"], 0.3)
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self.assertIsNotNone(run.evidence["settle_s"])
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self.assertTrue(any("idle ref:" in ln for ln in run.lines))
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def test_fans_left_running_fail_with_the_reference_in_the_message(self):
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def on_command(line):
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if line == "M8":
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self.duty(65535, 43278)
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self.fc.state["cool"]["phase"] = "run"
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self.fans(6753, 3212, 3328)
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# M9 ignored: the run profile stays on
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self.grbl.on_command = on_command
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run = Run("test", "cooling.fans-quiet-after-motion", "t")
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ctx = Context(run, None, helpers.make_test("cooling.fans-quiet-after-motion", []))
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with self.assertRaises(Failed) as cm:
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cooling.fans_quiet(ctx)
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self.assertIn("did not return to the idle profile", str(cm.exception))
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self.assertIn("idle reference", str(cm.exception))
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self.assertIn("65535", str(cm.exception))
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def test_a_reference_that_never_settles_fails_early_and_says_so(self):
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def churn():
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seq = (1000, 4000, 2500, 700, 3300, 1600, 4200) # aperiodic against the sampler
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i = 0
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while not self.grbl._stop:
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v = seq[i % len(seq)]
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i += 1
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self.fans(v, v, v)
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time.sleep(0.03)
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threading.Thread(target=churn, daemon=True).start()
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run = Run("test", "cooling.fans-quiet-after-motion", "t")
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ctx = Context(run, None, helpers.make_test("cooling.fans-quiet-after-motion", []))
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with self.assertRaises(Failed) as cm:
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cooling.fans_quiet(ctx)
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self.assertIn("never settled to an idle reference", str(cm.exception))
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self.assertEqual(self.grbl.commands, []) # nothing was jogged
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if __name__ == "__main__":
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unittest.main()
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class GateOffTests(unittest.TestCase):
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"""cooling.gate-off against a scripted engine: the fake forgectrl
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re-reads the ceiling at every M8 (as the engine reloads its tunables
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at run start), trips OVERTEMP when the coolant is over it, skips the
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gate and reports gates_off when the ceiling sits at its top, and
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writes the run-start line the test looks for."""
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TOP, BOTTOM = 60.0, 5.0
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def setUp(self):
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self.fc = helpers.FakeForgectrl().start()
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self.grbl = FakeGrbl()
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self.saved = (cooling.VERDICT_WAIT_S, cooling.SESSION_END_WAIT_S)
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cooling.VERDICT_WAIT_S = 3
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cooling.SESSION_END_WAIT_S = 3
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self.fc.state["status"] = dict(self.fc.state["status"],
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coolant={"down_c": 22.4, "up_c": 22.3, "pump": True, "tec": False},
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gates_off=[])
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self.fc.state["cool"] = {"phase": "idle", "verdict": "OK", "fire_ok": False, "hold": False,
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"gates_off": []}
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self.fc.state["settings"].update({"cool_temp_max": "", "cool_temp_resume": ""})
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self.log_line = True # the engine writes its run-start line
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self.report_off = True # the engine reports the off gate
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self.trips = True # the engine trips a low ceiling
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self.sessions = 0 # run sessions the engine saw (M8 with the phase not run)
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self._describe()
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self.grbl.on_command = self._engine
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self.fc.on_post = self._on_post
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def tearDown(self):
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cooling.VERDICT_WAIT_S, cooling.SESSION_END_WAIT_S = self.saved
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self.grbl.close()
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self.fc.stop()
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# -- the scripted machine --------------------------------------------------
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def ceiling(self):
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v = self.fc.state["settings"].get("cool_temp_max") or ""
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return float(v) if v else 33.0
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def _describe(self):
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"""/settings carries the gates table the way forgectrl's gates.c
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publishes it, classified from the stored value."""
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v = self.ceiling()
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state = "off" if v >= self.TOP else ("ok" if 25 <= v <= 38 else "warn")
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self.fc.state["settings"]["gates"] = {
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"cool_temp_max": {"gate": "coolant_max", "def": 33, "lo": self.BOTTOM, "hi": self.TOP,
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"band": [25, 38], "off": "high", "value": v, "state": state}}
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def _on_post(self, path, form):
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"""The real settings reply re-classifies the gates from the new values."""
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if path != "/settings":
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return None
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self.fc.state["settings"].update(form)
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self._describe()
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return (200, self.fc.state["settings"])
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def _engine(self, line):
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"""M8 opens a run session: the engine re-reads the ceiling and
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ticks the gate. M9 ends it a report period later (the phase
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leaves run); a hold taken against the old ceiling stands until
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the next session re-reads."""
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self._describe()
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cool = self.fc.state["cool"]
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if line == "M9":
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def end():
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time.sleep(0.3)
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cool["phase"] = "smoke"
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time.sleep(0.2)
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cool["phase"] = "idle"
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threading.Thread(target=end, daemon=True).start()
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return
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if line != "M8":
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return
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self.sessions += 1
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cool["phase"] = "run"
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v = self.ceiling()
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off = v >= self.TOP
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if off and self.log_line:
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self.fc.state["logs_tail"]["text"] += (
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"Aug 21 12:00:00 forgectrl: cool: gate coolant_max OFF: cool_temp_max = 60 "
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"(the high end of 5 to 60; recommended 25 to 38, default 33)\n")
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gates_off = ["coolant_max"] if off and self.report_off else []
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if not off and self.trips and 22.3 > v:
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cool.update(verdict="OVERTEMP", fire_ok=False, hold=True, gates_off=gates_off)
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else:
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cool.update(verdict="OK", fire_ok=True, hold=False, gates_off=gates_off)
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self.fc.state["status"]["gates_off"] = gates_off
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def run_test(self):
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run = Run("test", "cooling.gate-off", "t")
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ctx = Context(run, None, helpers.make_test("cooling.gate-off", []))
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cooling.gate_off(ctx)
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return run
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def settings_posts(self):
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return [f for p, f in self.fc.posts if p == "/settings"]
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# -- cases ------------------------------------------------------------------
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def test_trip_then_off_then_restored_passes(self):
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run = self.run_test()
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self.assertEqual(run.evidence["trip"]["verdict"], "OVERTEMP")
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self.assertEqual(run.evidence["off"]["gates_off"], ["coolant_max"])
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self.assertEqual(run.evidence["restored"]["verdict"], "OK")
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posts = self.settings_posts()
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self.assertEqual(posts[0], {"cool_temp_max": "6.0", "cool_temp_resume": "5.0"})
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self.assertEqual(posts[1], {"cool_temp_max": "60.0", "cool_temp_resume": ""})
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self.assertEqual(posts[-1], {"cool_temp_max": "", "cool_temp_resume": ""})
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self.assertEqual(self.fc.state["settings"]["cool_temp_max"], "")
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self.assertEqual(self.grbl.commands.count("M8"), 3)
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self.assertEqual(self.grbl.commands.count("M9"), 3)
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def test_an_engine_that_does_not_trip_fails_and_restores(self):
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self.trips = False
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with self.assertRaises(Failed) as cm:
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self.run_test()
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self.assertIn("did not trip", str(cm.exception))
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self.assertEqual(self.settings_posts()[-1], {"cool_temp_max": "", "cool_temp_resume": ""})
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self.assertEqual(self.fc.state["settings"]["cool_temp_max"], "")
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# The restore cycles a run session so the engine re-reads the
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# restored values; the bench is not left holding on the test's.
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self.assertEqual(self.grbl.commands.count("M8"), 2)
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self.assertEqual(self.grbl.commands.count("M9"), 2)
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self.assertEqual(self.fc.state["cool"]["verdict"], "OK")
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def test_every_session_waits_for_the_previous_one_to_end(self):
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"""Each M8 must find the engine out of phase run, or the engine
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never re-reads: the bench failure behind this case sent M9 and
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the next M8 300 ms apart and the 1 Hz report pipeline swallowed
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the session end."""
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seen = []
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inner = self._engine
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def engine(line):
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if line == "M8":
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seen.append(self.fc.state["cool"]["phase"])
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inner(line)
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self.grbl.on_command = engine
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self.run_test()
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self.assertEqual(seen, ["idle", "idle", "idle"])
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self.assertEqual(self.sessions, 3)
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def test_an_engine_that_hides_the_off_gate_fails(self):
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self.report_off = False
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with self.assertRaises(Failed) as cm:
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self.run_test()
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self.assertIn("gates_off", str(cm.exception))
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self.assertEqual(self.fc.state["settings"]["cool_temp_max"], "")
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def test_a_missing_run_start_log_line_fails(self):
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self.log_line = False
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with self.assertRaises(Failed) as cm:
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self.run_test()
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self.assertIn("run-start log line", str(cm.exception))
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self.assertEqual(self.fc.state["settings"]["cool_temp_max"], "")
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def test_a_custom_ceiling_is_restored_verbatim(self):
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self.fc.state["settings"].update({"cool_temp_max": "30", "cool_temp_resume": "28"})
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self._describe()
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run = self.run_test()
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self.assertEqual(run.evidence["orig"], {"cool_temp_max": "30", "cool_temp_resume": "28"})
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self.assertEqual(self.settings_posts()[-1], {"cool_temp_max": "30", "cool_temp_resume": "28"})
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self.assertEqual(self.fc.state["settings"]["cool_temp_max"], "30")
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class FanGateTests(unittest.TestCase):
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"""cooling.fan-gate-trips against a scripted engine: the fake reads the
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floors at every M8 (the engine reloads at run start), holds every fan
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in grace for the configured seconds, then judges the bench readings
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(exhaust 6753, intakes 3212/3328, air assist 10997 rpm, purge 628)
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against the floors: a floor a reading cannot meet trips AIRFLOW three
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ticks after the grace, a floor of zero reads off."""
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READINGS = {"exhaust": 6753, "intake_1": 3212, "intake_2": 3328, "air_assist": 10997, "purge": 628}
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FLOORS = {"exhaust": ("cool_tach_exhaust_min_rpm", 3700.0, 20000.0),
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"intake_1": ("cool_tach_intake_min_rpm", 1800.0, 20000.0),
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"intake_2": ("cool_tach_intake_min_rpm", 1800.0, 20000.0),
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"air_assist": ("cool_tach_air_assist_min_rpm", 6000.0, 30000.0),
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"purge": ("cool_purge_min_current", 300.0, 1023.0)}
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GATE_OF = {"exhaust": "exhaust", "intake_1": "intake", "intake_2": "intake",
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"air_assist": "air_assist", "purge": "purge"}
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|
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def setUp(self):
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self.fc = helpers.FakeForgectrl().start()
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self.grbl = FakeGrbl()
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self.saved = (cooling.VERDICT_WAIT_S, cooling.SESSION_END_WAIT_S, cooling.FAN_TRIP_WAIT_S)
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cooling.VERDICT_WAIT_S = 4
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cooling.SESSION_END_WAIT_S = 3
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cooling.FAN_TRIP_WAIT_S = 4
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self.fc.state["status"] = dict(self.fc.state["status"], gates_off=[])
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self.fc.state["cool"] = {"phase": "idle", "verdict": "OK", "fire_ok": False, "hold": False,
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"gates_off": [], "fan_gates": {}}
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for key, _d, _h in self.FLOORS.values():
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self.fc.state["settings"].setdefault(key, "")
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self.fc.state["settings"].setdefault("cool_fan_grace_s", "")
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self.trips = True # the engine trips an unmeetable floor
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self.reports_off = True # the engine reports a zero floor as off
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self.grace_scale = 0.1 # seconds of fake grace per configured second
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self._describe()
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self.grbl.on_command = self._engine
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self.fc.on_post = self._on_post
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|
|
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def tearDown(self):
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cooling.VERDICT_WAIT_S, cooling.SESSION_END_WAIT_S, cooling.FAN_TRIP_WAIT_S = self.saved
|
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self.grbl.close()
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self.fc.stop()
|
|
|
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def setting(self, key, default):
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v = self.fc.state["settings"].get(key) or ""
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return float(v) if v else default
|
|
|
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def _describe(self):
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|
gates = {}
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for fan, (key, default, hi) in self.FLOORS.items():
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v = self.setting(key, default)
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gates[key] = {"gate": self.GATE_OF[fan], "def": default, "lo": 0.0, "hi": hi,
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"band": [default * 0.7, default * 1.4], "off": "low", "value": v,
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"state": "off" if v <= 0 else "ok"}
|
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g = self.setting("cool_fan_grace_s", 15.0)
|
|
gates["cool_fan_grace_s"] = {"gate": None, "def": 15.0, "lo": 0.0, "hi": 120.0, "band": [5, 30],
|
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"off": "none", "value": g, "state": "ok"}
|
|
self.fc.state["settings"]["gates"] = gates
|
|
|
|
def _on_post(self, path, form):
|
|
if path != "/settings":
|
|
return None
|
|
self.fc.state["settings"].update(form)
|
|
self._describe()
|
|
return (200, self.fc.state["settings"])
|
|
|
|
def _engine(self, line):
|
|
self._describe()
|
|
cool = self.fc.state["cool"]
|
|
if line == "M9":
|
|
def end():
|
|
time.sleep(0.3)
|
|
cool["phase"] = "idle"
|
|
# the fan fault is the session's: it ends with it
|
|
cool.update(verdict="OK", fire_ok=True, hold=False, reason="")
|
|
for g in cool.get("fan_gates", {}).values():
|
|
g["state"] = "idle"
|
|
threading.Thread(target=end, daemon=True).start()
|
|
return
|
|
if line != "M8":
|
|
return
|
|
cool["phase"] = "run"
|
|
floors = {fan: self.setting(key, default) for fan, (key, default, _h) in self.FLOORS.items()}
|
|
off = sorted({self.GATE_OF[f] for f, v in floors.items() if v <= 0}) if self.reports_off else []
|
|
cool.update(verdict="OK", fire_ok=True, hold=False, resume_ok=True, reason="", gates_off=off,
|
|
fan_gates={f: {"reading": self.READINGS[f], "floor": floors[f],
|
|
"state": "off" if floors[f] <= 0 else "grace"} for f in floors})
|
|
self.fc.state["status"]["gates_off"] = off
|
|
grace = self.setting("cool_fan_grace_s", 15.0) * self.grace_scale
|
|
|
|
def judge():
|
|
time.sleep(grace)
|
|
if cool["phase"] != "run":
|
|
return
|
|
for f in floors:
|
|
if floors[f] > 0:
|
|
cool["fan_gates"][f]["state"] = "ok" if self.READINGS[f] >= floors[f] else "under"
|
|
time.sleep(0.3)
|
|
if cool["phase"] != "run" or not self.trips:
|
|
return
|
|
for f in floors:
|
|
if 0 < floors[f] > self.READINGS[f]:
|
|
cool["fan_gates"][f]["state"] = "TRIPPED"
|
|
cool.update(verdict="AIRFLOW", fire_ok=False, hold=True, resume_ok=False,
|
|
reason="AIRFLOW: %s %d under the %d floor for 3 s - hold, no resume this job"
|
|
% (f, self.READINGS[f], floors[f]))
|
|
break
|
|
threading.Thread(target=judge, daemon=True).start()
|
|
|
|
def run_test(self):
|
|
run = Run("test", "cooling.fan-gate-trips", "t")
|
|
ctx = Context(run, None, helpers.make_test("cooling.fan-gate-trips", []))
|
|
cooling.fan_gate_trips(ctx)
|
|
return run
|
|
|
|
def settings_posts(self):
|
|
return [f for p, f in self.fc.posts if p == "/settings"]
|
|
|
|
def test_trip_purge_off_and_restore_pass(self):
|
|
run = self.run_test()
|
|
ev = run.evidence
|
|
self.assertEqual(ev["exhaust_trip"]["cool"]["verdict"], "AIRFLOW")
|
|
self.assertEqual(ev["exhaust_trip"]["gate"]["state"], "TRIPPED")
|
|
self.assertEqual(ev["purge_trip"]["gate"]["state"], "TRIPPED")
|
|
self.assertEqual(ev["exhaust_off"]["cool"]["gates_off"], ["exhaust"])
|
|
self.assertTrue(all(g["state"] == "ok" for g in ev["restored"].values()))
|
|
posts = self.settings_posts()
|
|
self.assertEqual(posts[0], {"cool_tach_exhaust_min_rpm": "20000.0", "cool_fan_grace_s": "8"})
|
|
self.assertEqual(posts[-1], {"cool_tach_exhaust_min_rpm": "", "cool_purge_min_current": "",
|
|
"cool_fan_grace_s": ""})
|
|
self.assertEqual(self.grbl.commands.count("M8"), 4)
|
|
self.assertEqual(self.grbl.commands.count("M9"), 4)
|
|
|
|
def test_an_engine_that_does_not_trip_fails_and_restores(self):
|
|
self.trips = False
|
|
with self.assertRaises(Failed) as cm:
|
|
self.run_test()
|
|
self.assertIn("did not trip", str(cm.exception))
|
|
self.assertEqual(self.settings_posts()[-1], {"cool_tach_exhaust_min_rpm": "", "cool_purge_min_current": "",
|
|
"cool_fan_grace_s": ""})
|
|
self.assertEqual(self.fc.state["cool"]["verdict"], "OK")
|
|
|
|
def test_an_engine_that_hides_an_off_floor_fails(self):
|
|
self.reports_off = False
|
|
with self.assertRaises(Failed) as cm:
|
|
self.run_test()
|
|
self.assertIn("lacks exhaust", str(cm.exception))
|
|
self.assertEqual(self.fc.state["settings"]["cool_tach_exhaust_min_rpm"], "")
|