From 3b622d3d17086dbfe3e63e4e3f0adc447dc47493 Mon Sep 17 00:00:00 2001
From: Henrik Muehe <henrik.muehe@gmail.com>
Date: Sun, 3 May 2026 11:50:49 +0200
Subject: [PATCH] ExternalAxis: enforce soft limits in execute_to_mm and
 enqueue_target_mm

Soft limits in machine coords (min_w/max_w from aux.json) were only
checked by gplan. UI jog/move endpoints went through ExternalAxis
directly without any check, so the W+ button at home would happily
push past max_w into a physical crash.

Add _check_soft_limit(target_abs_mm) called by both motion paths:
the synchronous execute_to_mm (UI) and the non-blocking
enqueue_target_mm (planner). Boundaries inclusive within a 1e-4
epsilon for floating-point round-trip stability. Skipped when the
axis isn't homed, matching the standard bbctrl convention that
soft limits are gated by homing state. Skipped when max <= min
(disabled).

Tested locally:
- pre-home: 200mm allowed (jog-out-of-trouble path)
- post-home: 0 and 134 (boundaries) accepted
- post-home: 135 and -1 rejected with clear error
- 134.00005 accepted (within epsilon), 134.001 rejected
- enqueue path also rejects, propagating up through Planner.next()
- max==min config skips check
---
 src/py/bbctrl/ExternalAxis.py | 56 ++++++++++++++++++++++++++++++++++-
 1 file changed, 55 insertions(+), 1 deletion(-)

diff --git a/src/py/bbctrl/ExternalAxis.py b/src/py/bbctrl/ExternalAxis.py
index add6856..a963e16 100644
--- a/src/py/bbctrl/ExternalAxis.py
+++ b/src/py/bbctrl/ExternalAxis.py
@@ -140,6 +140,51 @@ class ExternalAxis(object):
         except Exception:
             return 0.0
 
+    # ------------------------------------------------------- soft limits
+
+    def _soft_limits(self):
+        """Return (min_mm, max_mm) in machine coords, or (None, None)
+        if soft limits are disabled (max <= min)."""
+        try:
+            lo = float(self.aux._cfg.get('min_w', 0.0))
+            hi = float(self.aux._cfg.get('max_w', 0.0))
+        except Exception:
+            return (None, None)
+        if hi <= lo:
+            return (None, None)
+        return (lo, hi)
+
+    def _check_soft_limit(self, target_abs_mm):
+        """Raise ExternalAxisError if target_abs_mm is outside the
+        configured soft limits. Skips the check when the axis isn't
+        homed (matching the standard bbctrl convention that soft
+        limits are gated by homing state) - that lets the user jog
+        away from a stuck position before homing without false
+        rejections.
+
+        Called by both planner-driven motion (enqueue_target_mm) and
+        UI motion (execute_to_mm), so this is the single source of
+        truth regardless of which path triggered the move."""
+        # Honour the homing gate.
+        try:
+            homed = bool(self.aux._homed)
+        except Exception:
+            homed = False
+        if not homed:
+            return
+        lo, hi = self._soft_limits()
+        if lo is None:
+            return
+        # Use a tiny epsilon so floating-point round-trip targets
+        # right at the boundary aren't rejected.
+        eps = 1e-4
+        target = float(target_abs_mm)
+        if target < lo - eps or target > hi + eps:
+            raise ExternalAxisError(
+                '%s axis target %.4f mm is outside soft limits '
+                '[%.3f, %.3f] mm' % (
+                    self.axis_letter.upper(), target, lo, hi))
+
     # ----------------------------------------------------------- conversion
 
     def mm_to_steps_delta(self, delta_mm):
@@ -267,6 +312,9 @@ class ExternalAxis(object):
         endpoints which may want to wait. Most planner-driven motion
         goes through enqueue_target_mm instead, which is non-blocking.
 
+        Soft limits are enforced here (not just in gplan) because the
+        UI jog/move endpoints don't go through the planner.
+
         Updates state.<axis>p immediately on completion. For the
         planner-driven path that goes through enqueue_target_mm, the
         AVR's own ap reports drive state.<axis>p instead."""
@@ -275,6 +323,7 @@ class ExternalAxis(object):
                 'External axis %r not available (aux disabled or '
                 'not connected)' % self.axis_letter)
 
+        self._check_soft_limit(ext_mm)
         steps, abs_mm = self._compute_move(ext_mm)
         if steps == 0:
             self._pos_mm = abs_mm
@@ -304,10 +353,15 @@ class ExternalAxis(object):
         the next line block computes the correct delta.
 
         The Planner.__encode hook calls this so the AVR comm thread
-        is never blocked by serial RPCs to the ESP."""
+        is never blocked by serial RPCs to the ESP.
+
+        Soft limits are enforced here (defense in depth on top of
+        gplan). Raising stops the planner via Planner.next's
+        exception handler."""
         if not self.enabled:
             raise ExternalAxisError(
                 'External axis %r not available' % self.axis_letter)
+        self._check_soft_limit(ext_mm)
         steps, abs_mm = self._compute_move(ext_mm)
         # Internal mirror only - drives subsequent delta computation.
         # state.<axis>p is left to the AVR's status reports.