Write the drivetrain block at install, since the firmware now demands it
This commit is contained in:
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842d95eeca
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6f88b00856
GPG Key ID:
D4A6C394DF13F1D7
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@ -435,11 +435,12 @@ Branch `worktree-hardware-config` (worktree at `.claude/worktrees/hardware-confi
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| 3 | `hardware.ini`: `[Board]` / `[Hardware]` typed, layered over `config.ini`, shadowed keys warned | **done**, 5 tests |
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| 4 | Resolution chain `--hardware` / `$FGC_HARDWARE` / `/etc/...` / beside `config.ini` | **done**, 2 tests |
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| 8 | `config/hardware.example.ini` documenting the shape | **done**, and the `hardware/lattepanda-iota/` setup kit now exists too (`install.sh`, `packages.txt`, three precondition files) |
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| 8 | `install.sh` writes the drivetrain block | **done.** One `[Motor.<axis>]` per declared axis, with `--r-sense` / `--run-current` / `--homing-current` / `--travel-deg` / `--steps-per-rev` / `--sw-mode` for what an installer knows and commented `; TODO` lines for what nothing can probe. Needed because the firmware now refuses to move undeclared |
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| 10 | Presence reconciliation (declared vs found) | **done**, 13 tests. `HardwarePresence.h` compares `[Hardware]` against what came up; warn-only by default, refusing under `[Features] strict_presence` with `--degraded` as the field-triage escape (decision 4) |
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| 11 | `test hardware` | **done**, 11 tests. Five leaves (`axes` / `motor` / `imu` / `env` / `camera`) under a new `hardware` subsystem; included in a bare `test`, and deliberately not gated on a homed gimbal. Nothing declared reports SKIP, never PASS |
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| 5 | Delete the `Application.cpp` speed literals | **done**, 13 tests. Decision 2 answered: speed is declared as `[Motor.<axis>] scan_speed_deg_s` (default **8.0 deg/s**) and converted per tower through `counts_per_deg` (`AxisSpeed.h`). The literals sent 36.4 deg/s against an intended 21.8 |
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| 6 | Config handshake — **host half** | **done**, 13 tests. `FirmwareConfig.h` parses `NEED` and plans the `SET` lines; unanswered keys and unknown keys are reported separately. `[Features] mock_needcfg` makes the simulated controller run the handshake, so the host half is verified with no firmware. **The firmware half is not written** |
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| 6 | Config handshake — **firmware half** | **written, NOT compile-verified.** `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. Parser verified locally (30 native tests, g++); the rest type-checks against stubs on both board branches but has never been built by PlatformIO or run on hardware |
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| 6 | Config handshake — **firmware half** | **done and built** on both targets 2026-09-18 (iota_rp2040 and leonardo, `./deploy.sh --compile-only`); behaviour still unproven on a running rig. `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`. **Behaviour on a running rig is the one check still outstanding** |
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| 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` |
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Presence reconciliation (§10) changes nothing on a tower without a `hardware.ini`: absent is
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@ -299,17 +299,25 @@ commit `aab1925`.
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| 2 | **Phase 2 gate: RP2040 + TMC5160-BOB at 3.3 V** | **PASSED** on tower 121, 2026-09-15: `IOIN Y=0x3000001E version=0x30`, encoder reading (`X_ENC`), one axis, `speed=3000` |
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| 2 | `src/platform.h` — reset cause and free RAM behind one interface per MCU family | **done** |
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| 2 | `Serial.begin()` moved ahead of all hardware init, so a wedged image stays flashable | **done** |
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| 2 | `[env:iota_rp2040]` PlatformIO target (arduino-pico core, 8 MB flash) | **done and built** on tower 121, 2026-09-15: 49452 B flash (0.6 % of 8 MB), 9068 B RAM. `leonardo` still builds (19254 B) and the 22 native tests still pass |
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| 2 | `[env:iota_rp2040]` PlatformIO target (arduino-pico core, 8 MB flash) | **done and built.** Latest, 2026-09-18, with the config handshake: **iota_rp2040** 51716 B flash (0.6 % of 8 MB), 9108 B RAM (3.5 %); **leonardo** 22646 B flash (**79 % of 28 KB**), 939 B RAM (36.7 %). Both from `./deploy.sh --compile-only` against towers 121 and 111; 33 native tests pass (`pio test -e native`) |
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| 2 | Per-board pin map + `NUM_AXES` in `platform_leonardo.h` / `platform_iota.h`, as-built wiring | **done** — compile-time, not yet generated from `hardware.ini` |
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| 2 | Pins + `NUM_AXES` generated from `hardware.ini` | **not started** — needs the config plan's phase 2 first |
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| 3 | Yaw homing on the real drivetrain | **done** — the endstop was being sheared through at full torque; homing at 189 mA holds. See below |
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| 1 | Everything else | blocked on [hardware-config-plan.md](hardware-config-plan.md) |
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> **Not compile-verified.** PlatformIO is not installed on the dev box and the firmware is built
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> *remotely on the tower* by `firmware/deploy.sh`. What was verified locally: both branches of
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> `platform.h` syntax-check against stub headers — the AVR branch under `gnu++11` (what the Arduino AVR
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> core uses) and the RP2040 branch under `gnu++17` (what arduino-pico uses) — and an unrecognised
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> architecture fails on the `#error` rather than compiling silently.
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> **Where the firmware gets built.** PlatformIO is not installed on the dev box; the firmware is built
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> *remotely on a tower* by `firmware/deploy.sh --compile-only`. Locally, the Arduino-free sources
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> (`command_parse.cpp` and its native tests) compile and run under plain g++, and the rest
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> syntax-checks against stub headers on both branches — the AVR under `gnu++11` and the RP2040 under
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> `gnu++17`, with an unrecognised architecture failing on the `#error` rather than compiling silently.
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> That catches typos and signatures; it says nothing about size or behaviour, so a remote build is
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> still the gate.
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>
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> **Flash headroom is now the constraint on the Delta fleet.** The ATmega32U4 build sits at **79 % of
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> its 28 KB** (6026 B left), up from 19254 B at the phase 2 gate — that growth is everything since:
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> `BOOTSEL`, `CURRENT`, the reduced homing current, `STOP` ending a homing, and the config handshake.
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> RP2040 flash is a non-issue at 0.6 % of 8 MB. Deleting the drivetrain fields from `MOTOR_CONFIG`
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> (config plan §14) now buys space as well as removing a duplicate definition.
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>
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> To actually build it: `cd firmware && ./deploy.sh --compile-only` compiles on the device without
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> flashing. That rsyncs over the tower's firmware source tree, so it is a deliberate step, not one to
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@ -230,8 +230,26 @@ Then prove the program finds it **with nothing in the environment** - no
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### The drivetrain block
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`install.sh` does not write this one - no probe can read a sense resistor off a
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board - so add it by hand, one `[Motor.<axis>]` block per axis:
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**`install.sh` now writes this block**, one `[Motor.<axis>]` per declared axis —
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it has to, because the firmware refuses to move until it has been told these
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(see the config handshake in [configuration.md](configuration.md)). What it still
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cannot do is *probe* them: no reading of a board tells you its sense resistor.
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So pass what you know and it writes the values; omit anything and it writes a
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commented `; TODO` line naming what to measure:
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```bash
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./install.sh --stdout --axes yaw \
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--r-sense 0.075 --run-current 756 --homing-current 200 \
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--travel-deg 340 --steps-per-rev 1210778 --sw-mode 0
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```
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A `TODO` line is **commented, not a placeholder value**, and deliberately: these
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keys are numeric, and a non-numeric value makes the program refuse to start with
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a message about a config key. Left absent, it starts and names exactly which keys
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that axis is missing and that it will not move — the useful failure.
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The block it writes looks like this:
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```ini
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[Motor.yaw]
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@ -20,6 +20,22 @@
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# --env none (default: none) ambient sensor model, or none
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# --cameras rgb (default: rgb) expected [Camera.<name>] blocks
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#
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# The drivetrain, per axis. The firmware REFUSES TO MOVE until it has been told
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# these (docs/configuration.md, the config handshake), so an axis left undeclared
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# is an axis that will sit in NEEDCFG. Pass what you know; what you omit is
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# written as a commented line naming what has to be measured:
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#
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# --r-sense 0.075 sense resistor on that axis's TMC board (ohms)
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# --run-current 756 coil current for normal motion (mA RMS)
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# --homing-current 200 coil current while hunting an endstop (mA RMS)
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# --travel-deg 340 mechanical angle between the hard stops
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# --steps-per-rev 1210778 measured full travel, in counts
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# --sw-mode 0 TMC SW_MODE: 0 = no switches (StallGuard homing)
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#
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# These take ONE value, applied to the first axis in --axes. A second axis gets a
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# commented template: nothing here can be probed, and inventing a sense resistor
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# is how a driver gets cooked.
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#
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# Other flags:
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# --force overwrite an existing hardware.ini (backs it up first)
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# --no-apt-update skip 'apt-get update'
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@ -34,6 +50,10 @@ AXES="yaw,pitch"
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IMU="none"
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ENV_SENSOR="none"
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CAMERAS="rgb"
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# Empty means "not known at install time" -> written commented out, never as a
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# sentinel: these are numeric keys, and a non-numeric value makes the program
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# refuse to start rather than report the axis as undeclared.
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R_SENSE="" RUN_CURRENT="" HOMING_CURRENT="" TRAVEL_DEG="" STEPS_PER_REV="" SW_MODE=""
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DO_DEPS=0 DO_PRE=0 DO_HW=0 DO_VIMBA=0 PROBE_ONLY=0 TO_STDOUT=0 FORCE=0 APT_UPDATE=1
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VIMBA_SRC=""
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EXPLICIT=0
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@ -49,6 +69,12 @@ while [[ $# -gt 0 ]]; do
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--imu) IMU="$2"; shift ;;
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--env) ENV_SENSOR="$2"; shift ;;
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--cameras) CAMERAS="$2"; shift ;;
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--r-sense) R_SENSE="$2"; shift ;;
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--run-current) RUN_CURRENT="$2"; shift ;;
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--homing-current) HOMING_CURRENT="$2"; shift ;;
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--travel-deg) TRAVEL_DEG="$2"; shift ;;
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--steps-per-rev) STEPS_PER_REV="$2"; shift ;;
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--sw-mode) SW_MODE="$2"; shift ;;
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--vimba) VIMBA_SRC="$2"; DO_VIMBA=1; EXPLICIT=1; shift ;;
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--force) FORCE=1 ;;
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--no-apt-update) APT_UPDATE=0 ;;
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@ -267,6 +293,26 @@ do_vimba() {
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}
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# ------------------------------------------------------------ hardware.ini ---
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# Emit "key = value", or a commented-out line naming what has to be measured.
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#
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# Commented rather than a placeholder string on purpose: these keys are numeric,
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# and a non-numeric value makes the program refuse to start with a message about
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# a config key. Absent, it starts and reports the axis as undeclared - naming the
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# missing keys and which axis will not move, which is the useful failure.
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kv_or_todo() {
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local key="$1" value="$2" why="$3"
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if [[ -n $value ]]; then
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printf '%-18s = %s\n' "$key" "$value"
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return
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fi
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# Wrapped, and not merely for looks: ini.h sets INI_MAX_LINE to 200, and a
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# longer line is SPLIT rather than truncated, so its tail becomes a bogus
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# line and the whole file fails to parse. A generated file that cannot be
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# read is worse than one with a gap in it.
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printf '; TODO %s\n' "$key"
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printf '%s\n' "$why" | fold -s -w 72 | sed 's/^/; /' | sed 's/[[:space:]]*$//'
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}
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emit_hardware_ini() {
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local board mcu cam fw_env
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board="$(probe_board)"
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@ -329,6 +375,60 @@ i2c_addr = 0x44
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EOF
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fi
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# One [Motor.<axis>] block per axis. The firmware holds none of these itself
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# any more - it asks, and refuses to move until answered - so an axis without
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# a block here is an axis that will not turn.
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#
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# A value we were not given is written COMMENTED OUT, with what to measure.
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# Not as a placeholder string: these keys are numeric, and a non-numeric value
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# makes the program refuse to start, which is a worse failure than the axis
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# reporting itself undeclared.
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local ax first=1
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for ax in ${AXES//,/ }; do
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ax="$(echo "$ax" | tr -d '[:space:]')"
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[[ -z $ax ]] && continue
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echo
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echo "[Motor.$ax]"
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if [[ $first -eq 1 ]]; then
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kv_or_todo "r_sense_ohm" "$R_SENSE" \
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"the resistor fitted to THIS driver board - read it off the board, do not assume"
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kv_or_todo "run_current_ma" "$RUN_CURRENT" \
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"coil current for normal motion, mA RMS, from the motor's nameplate"
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kv_or_todo "homing_current_ma" "$HOMING_CURRENT" \
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"current while hunting an endstop. LOWER than run_current wherever the stop can be out-pushed: on this rig a screw-head stop was sheared straight past its mate at full torque"
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kv_or_todo "travel_deg" "$TRAVEL_DEG" \
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"mechanical angle between the hard stops. Rough is fine to start; every bearing inherits its error proportionally until 'gimbal heading setup' supersedes it"
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kv_or_todo "steps_per_rev" "$STEPS_PER_REV" \
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"measured full travel IN COUNTS - read it off a homing run. The only guard against a PHANTOM endstop"
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kv_or_todo "sw_mode" "$SW_MODE" \
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"TMC SW_MODE. 0 = no physical switches (StallGuard homing); set the bits if this axis has REFL/REFR wired"
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else
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echo "; Nothing here can be probed, and this is not the first axis, so the"
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echo "; values below are a template. Measure them on THIS axis."
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kv_or_todo "r_sense_ohm" "" "sense resistor on this axis's driver board"
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kv_or_todo "run_current_ma" "" "coil current for normal motion, mA RMS"
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kv_or_todo "homing_current_ma" "" "current while hunting an endstop"
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kv_or_todo "travel_deg" "" "mechanical angle between the hard stops"
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kv_or_todo "steps_per_rev" "" "measured full travel, in counts"
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kv_or_todo "sw_mode" "" "TMC SW_MODE (0 = no physical switches)"
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fi
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cat <<'EOF'
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; Speeds are DEGREES PER SECOND, not VMAX: a register value means different
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; things on different gear ratios, so it is not portable between towers. The
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; host converts through counts_per_deg and sends SPEED.
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scan_speed_deg_s = 8.0
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homing_speed_deg_s = 2.0
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center_speed_deg_s = 6.0
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; |XACTUAL - XENC| that means "position untrustworthy". 1500 is this mechanism's
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; starting point; re-measure it whenever the homing current changes, because the
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; free-running gap is coupled to it.
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enc_deviation = 1500
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; Is this axis's encoder aligned to XACTUAL and usable for hold and DIAG?
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has_encoder = true
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EOF
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first=0
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done
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local c
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for c in ${CAMERAS//,/ }; do
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c="$(echo "$c" | tr -d '[:space:]')"
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@ -370,7 +470,12 @@ do_hardware_ini() {
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board="$(probe_board)"
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if [[ $board != lattepanda-iota ]]; then
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warn "this kit is for the LattePanda IOTA; this machine reports '$board'"
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[[ $PROBE_ONLY -eq 1 ]] || die "refusing to apply IOTA preconditions to a $board"
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# --probe and --stdout change nothing on this machine: one reports what it
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# found, the other prints the file it WOULD write. Refusing them on a
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# non-IOTA only means the generator can never be exercised off a tower,
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# which is how a setup kit ends up untested.
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[[ $PROBE_ONLY -eq 1 || $TO_STDOUT -eq 1 ]] ||
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die "refusing to apply IOTA preconditions to a $board"
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fi
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if [[ $PROBE_ONLY -eq 1 ]]; then probe_report; exit 0; fi
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@ -1243,6 +1243,22 @@ struct Application::Impl {
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continue;
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}
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const bool is_yaw = need->axis == 'Y';
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// An axis the tower says it does not have. That is not a missing
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// declaration - it is a firmware built for more axes than this rig,
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// and answering would configure a driver that is not there. Same
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// class of fault as presence reconciliation catches, so it is named
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// that way rather than as a hole in hardware.ini.
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const char* axis_name = is_yaw ? "yaw" : "pitch";
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if (cfg.hardware.declared && !cfg.hardware.hasAxis(axis_name)) {
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LOG_ERROR << "firmware asked for axis " << need->axis << " (" << axis_name
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<< "), which this tower does not declare (axes "
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<< cfg.hardware.axesLabel()
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<< ") -- the firmware was built for more axes than the rig has; "
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"rebuild it for this board rather than declaring an axis that is "
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"not fitted";
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continue;
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}
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const auto src = is_yaw
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? axisConfigSource("yaw", cfg.geometry.yaw, cfg.drivetrain.yaw,
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yaw_current_, cfg.yaw_soft_margin_counts)
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