Finish migrating tower 111, and check only the pins hardware.ini declares

docs/hardware-config-plan.md

@@ -402,35 +402,39 @@ Deploy host-before-firmware (A.6). Fix the `Application.cpp:1040` literals in th
 existing fleet that drops yaw 50000 → 30000, a real behaviour change that wants a deliberate rig check
 rather than a silent correction.
 
-> ### ⚠️ Tower 111 is half migrated: host yes, firmware no - and must stay so for now
+> ### Tower 111 is migrated (2026-09-23 host, 2026-09-24 firmware)
 >
-> 2026-09-23, through `scripts/install-tower` with the Delta kit: 111 now has a
+> Through `scripts/install-tower` with the Delta kit. 111 has a `hardware.ini`
-> `hardware.ini` (yaw + pitch, MTi on `/dev/ttyS0`, SHT41 on `/dev/i2c-2`,
+> (yaw + pitch, MTi on `/dev/ttyS0`, SHT41 on `/dev/i2c-2`), its USB
-> declared and confirmed by `test hardware`), its USB preconditions, the current
+> preconditions, the current host, and firmware `a0b1e4a`. `test hardware`
-> host, and a `config.ini` with the keys `hardware.ini` owns commented out. It
+> passes every leaf, `hw_motor` included, and `install-tower --verify` is green.
-> homed and resumed capturing on the new host. A rollback copy of the previous
+> A rollback copy of the previous sources, binary, firmware source and
-> sources, binary and `config.ini` is in `~ggs/rollback-20260923/` on the tower.
+> `config.ini` is in `~ggs/rollback-20260923/` on the tower.
 >
-> **Every drivetrain value is still a `; TODO`**, because the Delta firmware held
+> The drivetrain was not invented, and not measured afresh either: it is what
-> register values (GLOBALSCALER / IRUN) and converting them to milliamps needs
+> the firmware it replaced (`af74190-dirty`) was running, converted to
-> each driver board's sense resistor, which has to be read off the board. So
+> `hardware.ini`'s units with the sense resistor read off the boards (75 mOhm,
-> **do not flash 111 yet**: the new firmware would sit in `NEEDCFG`, refusing to
+> both axes). Round-tripped through the host's own planners back to identical
-> move. The installer blocks the flash for exactly this reason.
+> registers: GLOBALSCALER 80 / 50, IRUN 31, homing at the same (the Delta never
+> had a reduced search current), `steps_per_rev` 177000 / 500000 (the guard
+> unchanged; measured spans are 182,374 / 572,004), SW_MODE 0x8A0 / 0x8A3,
+> ENC_DEVIATION 1500, homing and centring speeds equal to the old VMAX figures.
+> `travel_deg` 361.7 / 40.5 is the homed span over the landmark-calibrated
+> `counts_per_deg`, and the host confirmed it agrees with the calibration after
+> the first home on the new firmware. Homing repeated the old firmware's travel
+> to within 0.03 %.
 >
 > Two corrections to what this section used to say:
 >
 > - `test hardware` does **not** pass on the old firmware. An absent echo is
 >   reported as unconfirmable, not as a mismatch - but unconfirmable is still a
->   FAIL, by design (`checkDeclaredValues`, `checkPinsBuilt`): a check that could
+>   FAIL, by design: a check that could not happen must not read as a pass. So on
->   not happen must not read as a pass. On 111 `hw_axes`, `hw_imu`, `hw_env` and
+>   a Delta the gate before flashing is "everything but `hw_motor` green, and
->   `hw_camera` pass; `hw_motor` fails as "predates the pin echo". Phase 1's gate
+>   `hw_motor` failing only on missing echoes".
->   for a Delta is therefore "everything but `hw_motor` green, and `hw_motor`
->   failing only on missing echoes" until the firmware is flashed.
 > - Speed: `scan_speed_deg_s = 8.0` applies to **both** axes. On 111 that is VMAX
->   5638 for yaw but **157861 for pitch** (14114 counts/deg), above the 150000 it
+>   5638 for yaw but 157861 for pitch, above the 150000 it ran at; pitch logs an
->   ran at and far above the firmware's tuned-down 60000; pitch logged encoder
+>   occasional encoder tracking error just over the 400-count limit. Accepted for
->   tracking errors of 424 and 473 counts (limit 400) in its first minutes. Set
+>   now (2026-09-24); `[Motor.pitch] scan_speed_deg_s` is the knob.
->   `[Motor.pitch] scan_speed_deg_s` lower if that persists.
 
 ## 14. Firmware changes, collected
 
@@ -475,7 +479,7 @@ after the table.
 | 6  | Config handshake — **firmware half** | **done, and validated on tower 121.** `NEEDCFG` state (`ST` code `C`), `NEED` emitted with the banner, `SET <axis> <key> <value>`, `USE DEFAULTS`, and the init block split so the residual-motion stop still runs at boot. 33 native tests pass under `pio test -e native`. On the rig: the handshake was watched live, `HOME` refused with `ERR need config`, `RESET` did not escape the state, and `USE DEFAULTS` released it |
 | 6  | Adoption check generalised | **done**, 9 tests. `DUMP` echoes every host-owned value plus a `cfg_rx` bitmask; `test hardware motor` checks all of them, and reports an absent field as unconfirmable rather than as a mismatch against -1. Round trip NEED -> SET -> DUMP -> PASS verified against `mock_needcfg` |
 | 14 | Drivetrain out of `MOTOR_CONFIG` | **done.** The struct keeps pins and `homing_kind` only; `platform_iota.h` keeps its measurement record but no longer defines this tower's values. `USE DEFAULTS` now loads a shared **limp-home** set (`LIMP_*` in `config.h`) that is deliberately nobody's real values — slow speeds, generous margins, the gentle search current — so a tower still running them fails `test hardware motor` instead of looking configured. `SW_MODE` is derived from `homing_kind` rather than shared, because disabling the hardware stops on an axis that homes on real switches would remove its last protection. Flash cost, not saved: see the porting plan. Found a real bug on the way — `DIAG` read `normal_speed` / `center_speed` from the compile-time table, so it ran at compiled speeds rather than the tower's declared ones |
-| 14 | Pins and `NUM_AXES` generated from `hardware.ini` | **done, validated on tower 121** (2026-09-23): built from its `/etc` file, flashed, `DUMP` echoed `spi=2,3,0 cs=1 en=4`, `IOIN version=0x30`, and `test hardware motor` passed `yaw_pins` / `spi_pins`; a build against a copy without `[Pins]` failed with the reason. Leonardo: builds against a generated Delta `hardware.ini`; the pin echo costs **170 B of flash** (22,876 -> 23,046 B, 79.8% -> 80.4%, 5,626 B free) and no RAM - measured 2026-09-23, compile only, not yet flashed to a Delta. New `[Pins]` section; `firmware/tools/gen_wiring.py` generates `board_wiring.h` into the build directory from the tower's own file at build time, and refuses pins the board cannot use (RP2040 SPI0 groups, the Leonardo's fixed ICSP pins, duplicates, a board/env mismatch). No compiled-in fallback: no file or no `[Pins]` fails the build. `DUMP` echoes `cs=`/`en=` per axis and `spi=` on the RP2040; `test hardware motor` compares them with `[Pins]`. The loom tables moved to `hardware/<board>/pins.ini`. 18 generator tests (run without PlatformIO), 9 host tests |
+| 14 | Pins and `NUM_AXES` generated from `hardware.ini` | **done, validated on tower 121** (2026-09-23): built from its `/etc` file, flashed, `DUMP` echoed `spi=2,3,0 cs=1 en=4`, `IOIN version=0x30`, and `test hardware motor` passed `yaw_pins` / `spi_pins`; a build against a copy without `[Pins]` failed with the reason. Leonardo: builds against a generated Delta `hardware.ini`; the pin echo costs **84 B of flash** (22,876 -> 22,960 B, 79.8% -> 80.1%, 5,712 B free) and no RAM. It first cost 170 B, because the SPI echo was gated on `PIN_SPI_SCK`, which the AVR core also defines (for the fixed ICSP pins); it is gated on the RP2040 now. Flashed to tower 111 on 2026-09-24 (the 170 B build, which also reports `spi=15,16,14` - harmless, and gone at its next flash). New `[Pins]` section; `firmware/tools/gen_wiring.py` generates `board_wiring.h` into the build directory from the tower's own file at build time, and refuses pins the board cannot use (RP2040 SPI0 groups, the Leonardo's fixed ICSP pins, duplicates, a board/env mismatch). No compiled-in fallback: no file or no `[Pins]` fails the build. `DUMP` echoes `cs=`/`en=` per axis and `spi=` on the RP2040; `test hardware motor` compares them with `[Pins]`. The loom tables moved to `hardware/<board>/pins.ini`. 18 generator tests (run without PlatformIO), 9 host tests |
 | 6  | `NEEDCFG` understood host-side | **done**, 5 tests. `AxisState::NeedConfig` parsed from `ST` `C`, named in `DUMP` and the dashboard, and counted as telemetry arriving rather than as a dead link. The firmware enum APPENDS the state (5) rather than inserting it — inserting renumbered every later state and made a READY axis read back as ERROR |
 
 **Validated on tower 121.** The handshake was watched live on the rig, not inferred:

docs/roadmap.md

@@ -19,9 +19,9 @@ Keep entries dated; move shipped items into the reference docs.
     metrics come off the firmware clock instead of host `ST` sampling; plus a
     `PING`/`PONG` link-health command for `test system link`.
   - ⚠️ **This collides with AVR flash headroom.** Three new commands are the
-    kind of growth the ATmega32U4 no longer has room for — it sits at **80.4 %
+    kind of growth the ATmega32U4 no longer has room for — it sits at **80.1 %
-    of its 28 KB** (5626 B free, measured 2026-09-23 after the pin echo added
+    of its 28 KB** (5712 B free, measured 2026-09-24 after the pin echo added
-    170 B; 79.8 % before it), up from 19254 B at the phase 2 gate. The RP2040 is a non-issue at 0.6 % of 8 MB. So either these
+    84 B; 79.8 % before it), up from 19254 B at the phase 2 gate. The RP2040 is a non-issue at 0.6 % of 8 MB. So either these
     land RP2040-only behind the `platform_*.h` split, or the Delta fleet gets a
     deliberate answer on flash first — `PROGMEM` for the string tables, dropping
     a command, or accepting that the Delta is feature-frozen. Note §14 of the

hardware/lattepanda-3-delta/NOTES.md

@@ -27,6 +27,14 @@ rebuilt on Ubuntu 22.04 (GCC 11) and restarted with `--init --start`. It homed a
 resumed capturing. `test hardware`: axes, IMU, env and camera PASS; motor FAIL on
 the old firmware's missing echoes, as expected. Firmware NOT flashed.
 
+## Firmware flashed on tower 111, 2026-09-24 `[verified]`
+
+With the drivetrain converted from what the replaced firmware ran (see
+`docs/hardware-config-plan.md` section 13) and 75 mOhm sense resistors read off
+both boards. `tools/flash.sh` flashed it through the Leonardo's 1200-baud touch
+unchanged. The new firmware asked, the host answered, `test hardware` passed
+every leaf, and it homed to within 0.03 % of the old firmware's travel.
+
 ## What this kit has NOT done yet
 
 In particular:
@@ -34,14 +42,10 @@ In particular:
 - **`pins.ini` is not a traced loom.** It carries the numbers the firmware ran
   on before pins moved into `hardware.ini`. Trace one Delta's wiring and replace
   it with a table the way the IOTA's was done.
-- **The drivetrain is not known in the units `hardware.ini` uses.** The Delta's
+- **Other Delta towers' drivetrains are not known.** 111's values are 111's:
-  firmware carried register values (GLOBALSCALER 80 / 50, IRUN 31, SW_MODE
+  converted from the firmware it ran, with its own boards' sense resistors. Do
-  0x8A0 / 0x8A3, ENC_DEVIATION 1500). Turning them into milliamps needs each
+  not copy them to another tower without reading that tower's boards and
-  driver board's sense resistor, which has to be read off the board. Until it
+  firmware revision the same way.
-  is, the current keys stay `; TODO` - and so the installer will not flash the
-  new firmware, which would refuse to move without them.
-- **Flashing** keeps the Leonardo's own 1200-baud touch, which is how the Delta
-  fleet has always been flashed; `tools/flash.sh` does nothing extra for it.
 
 ## Migrating an existing Delta tower
 

scripts/install-tower

@@ -229,6 +229,18 @@ PYEOF
     echo "build=${build:-?} spi=${spi:--} Y=${y:--} P=${p:--}"
 }
 
+# Does what the firmware reports match what hardware.ini declares? Only the
+# declared fields count, as in `test hardware motor`: a Leonardo declares no SPI
+# pins (they are fixed), so whatever an older build reports for them is moot.
+pins_match() {
+    local now="$1" want="$2" f v
+    [[ -n $now ]] || return 1
+    for f in $want; do
+        v="${f#*=}"; [[ $v == - ]] && continue
+        [[ " $now " == *" $f "* ]] || return 1
+    done
+}
+
 # The same, as hardware.ini declares it, for comparison.
 declared_pins() {
     local spi="-" y="-" p="-" a b c
@@ -364,7 +376,7 @@ verify() {
     check "hardware.ini complete" "$([[ $todo -eq 0 ]] && echo 0 || echo 1)" "$todo TODO(s)"
     local now; now="$(firmware_report)"
     local want_pins; want_pins="$(declared_pins)"
-    check "firmware pins" "$([[ -n $now && ${now#* } == "$want_pins" ]] && echo 0 || echo 1)" \
+    check "firmware pins" "$(pins_match "$now" "$want_pins" && echo 0 || echo 1)" \
           "running ${now:-unknown}; declared $want_pins"
     run_hardware_test
     check "test hardware" "$TEST_RC" "$([[ $TEST_RC == 0 ]] && echo PASS || echo "exit $TEST_RC")"
@@ -648,7 +660,7 @@ fi
 (( todo_n > 0 )) && FW_BLOCK="hardware.ini still has $todo_n gap(s): the firmware would sit in NEEDCFG, or not build"
 want_pins="$( (HW="$HW_VIEW"; [[ $HW_APPEND_PINS -eq 1 ]] && { cat "$HW" "$KIT/pins.ini" > "$WORK/hw_pins.ini"; HW="$WORK/hw_pins.ini"; }; declared_pins) )"
 if [[ -n $FW_BLOCK ]]; then plan firmware blocked "$FW_BLOCK"
-elif [[ -n $S_FW_NOW && ${S_FW_NOW%% *} == "build=$S_FW_REV" && ${S_FW_NOW#* } == "$want_pins" ]]; then
+elif [[ -n $S_FW_NOW && ${S_FW_NOW%% *} == "build=$S_FW_REV" ]] && pins_match "$S_FW_NOW" "$want_pins"; then
     plan firmware skip "running $S_FW_REV, built with the declared pins"
 else
     plan firmware change "build $S_FW_REV and flash it (running: ${S_FW_NOW:-unknown}; declared $want_pins)"
@@ -907,7 +919,20 @@ if app_running; then
     say "running"
 elif [[ $WAS_RUNNING -eq 1 ]]; then
     read -r -a restart_args <<< "${S_ARGS:-}"
+    before="$(latest_log)"
     ( cd "$REPO" && "$FGC" start "${restart_args[@]}" ) > /dev/null && say "restarted as it was: fgc start${S_ARGS:+ $S_ARGS}"
+    # With --init it is homing now, and refuses a test until it is done: wait,
+    # or the checks below report a busy program as a failed one.
+    if [[ " ${S_ARGS:-} " == *" --init "* ]]; then
+        say "waiting for it to home before checking"
+        for _ in $(seq 1 420); do
+            log="$(latest_log)"
+            if [[ -n $log && $log != "$before" ]] && grep -qE 'Gimbal homed|homing (failed|timed out)|ERROR.*hom' "$log"; then break; fi
+            app_running || break
+            sleep 1
+        done
+        grep -hE 'Gimbal homed|homed .* travel' "$(latest_log)" 2>/dev/null | tail -3 | sed 's/^/   /'
+    fi
 else
     say "left stopped, as it was"
 fi