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Send the whole drivetrain on connect, so a restart is enough to retune

This commit is contained in:
pgdalmeida 2026-09-23 07:36:23 +02:00
parent 00c998301a
commit bd3a568508
Signed by: pedro.almeida
GPG Key ID: D4A6C394DF13F1D7
3 changed files with 124 additions and 56 deletions
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30
docs/configuration.md
View File

@ -731,10 +731,10 @@ full torque — the fire it is there to prevent.
### The config handshake — the firmware asks, `hardware.ini` answers
Today the firmware carries a full parameter table and **guesses** when the host
says nothing, so every drivetrain value exists in two places and the two can
disagree. Section 6 of the config plan replaces that: the firmware declares what
it needs and refuses to move until it has it.
The firmware used to carry a full parameter table and **guess** when the host
said nothing, so every drivetrain value existed in two places and the two could
disagree. It no longer guesses: it declares what it needs and refuses to move
until it has it.
```
firmware -> BOOT build=abc123
@ -767,11 +767,23 @@ Three rules, each protecting against a different silent failure:
> `ST` line — deliberately not red, and deliberately not "no telemetry": the link
> is fine and the axis is talking, it just has not been told what it is driving.
>
> **Status: the host half only.** The host answers `NEED` and the responder is
> verified end to end, but the firmware that *asks* is not written yet. Set
> `[Features] mock_needcfg = 1` to make the simulated controller run the
> handshake — emit `NEED` at start, reject `HOME` / `MOVE` / `ENABLE` until every
> requested key is answered — which is how this is exercised on a dev box.
> **Retuning needs only a restart.** The firmware asks exactly once, at boot,
> and only while it is in `NEEDCFG` — so the handshake alone would mean that
> editing `hardware.ini` and restarting the *host* changed nothing, because the
> board is already configured and says nothing to reply to. The host therefore
> re-sends the whole declared block on every connect, whether or not it was
> asked. Edit, restart, done; no re-flash.
>
> It also makes the handshake robust to a `NEED` line lost on the wire: an axis
> still sitting in `NEEDCFG` is completed by that re-send rather than refusing to
> move until someone notices.
>
> **Both halves are live**, and validated on tower 121: the firmware emits `NEED`
> at boot and refuses `HOME` / `MOVE` / `ENABLE` until every required key is
> answered, and the host answers it. On a dev box with no board attached, set
> `[Features] mock_needcfg = 1` to make the simulated controller run the same
> handshake, or `0` to have it stand in for a board that is already configured —
> which is what exercises the unprompted re-send.
### Why speed is declared in degrees per second

8
docs/hardware-porting-plan.md
View File

@ -361,8 +361,12 @@ The fix is to make the search weak enough that the screw wins:
Declared per tower in `hardware.ini` as `[Motor.yaw] homing_current_ma`, converted
to registers by the host and sent as `CURRENT` before every home — so retuning it
is a restart, not a reflash. See [configuration.md](configuration.md) for the keys
and `firmware/docs/hardware-notes.md` for the mechanism.
is a restart, not a reflash. **That is now true of the whole drivetrain block**:
the host re-sends every declared value on connect, not only the ones with their
own command. It was briefly true of the current alone, which made half a
`hardware.ini` edit take effect on a restart and half silently not. See
[configuration.md](configuration.md) for the keys and
`firmware/docs/hardware-notes.md` for the mechanism.
Three things this exposed, all since fixed:

74
src/core/Application.cpp
View File

@ -1243,7 +1243,51 @@ struct Application::Impl {
LOG_WARN << "unparseable NEED line from the firmware: " << line;
continue;
}
const bool is_yaw = need->axis == 'Y';
answerNeed(*need, /*asked=*/true);
}
}
// Every key the host can answer, by its canonical name. Used to re-send the
// whole declared set on connect - see resendDeclaredConfig().
static NeedRequest fullRequest(char axis) {
NeedRequest r;
r.axis = axis;
r.keys = {"steps_per_rev", "global_scaler", "run_irun", "homing_irun",
"center_count", "soft_margin", "enc_deviation", "normal_speed",
"homing_speed", "center_speed", "sw_mode", "has_encoder"};
return r;
}
// Push the declared drivetrain at the firmware whether or not it asked.
//
// The firmware asks exactly once, at boot, and only while it is in NEEDCFG.
// Without this, editing hardware.ini and restarting the HOST changes nothing
// - the board is already configured, so it says nothing, and the host has
// nothing to reply to. The tower keeps running the old values silently.
// Re-tuning would need a re-flash, which is seven seconds on a bench and a
// trip up a mast in the field.
//
// CENTER and MARGIN are sent again as SET here, having just gone out as
// their own commands. That is idempotent and costs two lines; keeping the
// set uniform is worth more than saving them.
//
// It also makes the handshake robust to a NEED line lost on the wire: an
// axis still in NEEDCFG is completed by this re-send rather than sitting
// there refusing to move.
void resendDeclaredConfig() {
for (const char* name : {"yaw", "pitch"}) {
if (!cfg.hardware.hasAxis(name)) continue;
answerNeed(fullRequest(name[0] == 'y' ? 'Y' : 'P'), /*asked=*/false);
}
}
// `asked` distinguishes the two callers. When the firmware ASKED, a key the
// host cannot supply is a startup failure - the axis stays in NEEDCFG and
// will not move, so it is an error. On a proactive re-send it means only
// "hardware.ini does not declare this one", and the firmware simply keeps
// what it already had; saying ERROR there would cry wolf on every start.
void answerNeed(const NeedRequest& need, bool asked) {
const bool is_yaw = need.axis == 'Y';
// An axis the tower says it does not have. That is not a missing
// declaration - it is a firmware built for more axes than this rig,
@ -1252,13 +1296,13 @@ struct Application::Impl {
// that way rather than as a hole in hardware.ini.
const char* axis_name = is_yaw ? "yaw" : "pitch";
if (cfg.hardware.declared && !cfg.hardware.hasAxis(axis_name)) {
LOG_ERROR << "firmware asked for axis " << need->axis << " (" << axis_name
LOG_ERROR << "firmware asked for axis " << need.axis << " (" << axis_name
<< "), which this tower does not declare (axes "
<< cfg.hardware.axesLabel()
<< ") -- the firmware was built for more axes than the rig has; "
"rebuild it for this board rather than declaring an axis that is "
"not fitted";
continue;
return;
}
const auto src = is_yaw
? axisConfigSource("yaw", cfg.geometry.yaw, cfg.drivetrain.yaw,
@ -1267,28 +1311,30 @@ struct Application::Impl {
cfg.drivetrain.pitch, pitch_current_,
cfg.pitch_soft_margin_counts);
const auto plan = planFirmwareConfig(*need, src);
const auto plan = planFirmwareConfig(need, src);
for (const auto& cmd : plan.sets) motor->sendCommand(cmd);
if (!plan.unanswered.empty()) {
if (!plan.unanswered.empty() && asked) {
std::string keys;
for (const auto& k : plan.unanswered) keys += (keys.empty() ? "" : ", ") + k;
LOG_ERROR << "firmware asked axis " << need->axis << " for " << keys
LOG_ERROR << "firmware asked axis " << need.axis << " for " << keys
<< " and hardware.ini does not declare "
<< (plan.unanswered.size() == 1 ? "it" : "them")
<< "; the axis stays in NEEDCFG and will not move";
}
if (!plan.unknown.empty()) {
if (!plan.unknown.empty() && asked) {
std::string keys;
for (const auto& k : plan.unknown) keys += (keys.empty() ? "" : ", ") + k;
LOG_ERROR << "firmware asked axis " << need->axis << " for " << keys
LOG_ERROR << "firmware asked axis " << need.axis << " for " << keys
<< ", which this host does not know -- the firmware is newer than the "
"host; upgrade the host rather than editing hardware.ini";
}
if (plan.complete())
if (asked && plan.complete())
LOG_INFO << "firmware config: answered " << plan.sets.size() << " keys for axis "
<< need->axis;
}
<< need.axis;
if (!asked && !plan.sets.empty())
LOG_INFO << "drivetrain re-sent to axis " << need.axis << ": " << plan.sets.size()
<< " values from hardware.ini";
}
// Convert this tower's declared milliamps into TMC register fields, once.
@ -1389,6 +1435,12 @@ struct Application::Impl {
};
sendCurrent('Y', yaw_current_);
sendCurrent('P', pitch_current_);
// And the rest of the declared drivetrain. CENTER/MARGIN/CURRENT above
// have always been re-sent on every start; the keys the config handshake
// added were not, so half the tuning took effect on a restart and half
// silently did not. This makes all of it behave the same way.
resendDeclaredConfig();
}
// Derive each axis's reachable degree window from the freshly homed soft