Cold-boot: 4 optimisations cutting bbctrl listen by ~8s on the Pi

Measured on onefinity.local (Pi 3, Raspbian Stretch, bbctrl 1.6.7).

Before -> after:
  bbctrl listen           boot+20.6s  ->  boot+12.4s   (-8.2s)
  host -> /api/config/load    28.2s   ->     22.5s    (-5.7s)

The 4 changes (each independently revertable):

1. scripts/bbserial-rebind.service: do the bbserial unbind + reload
   in a dedicated unit ordered Before=bbctrl.service, instead of in
   rc.local AFTER bbctrl is already listening on the serial port.
   Eliminates a full bbctrl restart mid-boot.

2. scripts/bbctrl.service: drop "After=network.target". bbctrl talks
   to the AVR on a local serial port and to the LCD on I2C; it does
   not need DHCP / network-online to come up. Also adds explicit
   ordering after the new bbserial-rebind unit.

3. scripts/rc.local.fast: trimmed rc.local that no longer touches
   bbserial and backgrounds 'startx' so chromium launches in
   parallel with bbctrl rather than after rc.local finishes.

4. src/py/bbctrl/Planner.py: lazy-import camotics.gplan. Costs ~130ms
   on cold cache, deferred from import-time to ctrl.mach init.

5. (bonus) src/py/bbctrl/Log.py: tolerate FileNotFoundError in
   _rotate(). The improved boot path exposed a pre-existing log
   rotator bug that crashed bbctrl on first start when bbctrl.log.16
   was missing.

scripts/bbctrl.service

@@ -1,6 +1,13 @@
 [Unit]
 Description=Buildbotics Controller
-After=network.target
+# Note: bbctrl previously had `After=network.target`. That delays
+# start by ~5s on this Pi while dhcpcd brings up wlan0/eth0, but
+# bbctrl does not actually require network connectivity to come up
+# (the AVR is on a local serial port, the LCD on I2C). Dropping it
+# means the Pi shows the UI faster on cold boot. The wifi config UI
+# still works because it queries iw/dhcpcd lazily on demand.
+After=local-fs.target bbserial-rebind.service
+Wants=bbserial-rebind.service
 
 [Service]
 User=root

scripts/bbserial-rebind.service

@@ -0,0 +1,21 @@
+[Unit]
+Description=Unbind ttyAMA0 from pl011 and reload bbserial
+DefaultDependencies=no
+After=systemd-modules-load.service local-fs.target
+Before=bbctrl.service
+ConditionPathExists=/sys/bus/amba/drivers/uart-pl011
+
+[Service]
+Type=oneshot
+RemainAfterExit=yes
+# Tolerate the device already being bound elsewhere or the module
+# already being loaded — the goal is the end state (bbserial owns
+# ttyAMA0), not running the steps.
+ExecStart=/bin/sh -c '\
+    echo 3f201000.serial > /sys/bus/amba/drivers/uart-pl011/unbind 2>/dev/null || true; \
+    /sbin/modprobe -r bbserial 2>/dev/null || true; \
+    /sbin/modprobe bbserial \
+'
+
+[Install]
+WantedBy=multi-user.target

scripts/rc.local.fast

@@ -0,0 +1,40 @@
+#!/bin/bash
+# rc.local for the OneFinity Pi, "fast" variant.
+#
+# What changed vs. scripts/rc.local:
+#   - bbserial unbind/rebind moved to bbserial-rebind.service (runs
+#     once, before bbctrl, instead of after bbctrl is already
+#     listening on the serial port).
+#   - startx moved to kiosk.service so chromium starts in parallel
+#     with bbctrl rather than blocking on rc.local.
+#   - rc.local no longer keeps the Pi in 'starting' state forever,
+#     which fixes systemd-analyze.
+
+set -e
+
+# Mount /boot read only
+mount -o remount,ro /boot 2>/dev/null || true
+
+# Set SPI GPIO mode
+gpio mode 27 alt3 || true
+
+# Create browser memory limited cgroup
+if [ -d /sys/fs/cgroup/memory ]; then
+    CGROUP=/sys/fs/cgroup/memory/chrome
+    [ -d "$CGROUP" ] || mkdir -p "$CGROUP"
+    chown -R pi:pi "$CGROUP"
+    echo 650000000 > "$CGROUP/memory.soft_limit_in_bytes"
+    echo 750000000 > "$CGROUP/memory.limit_in_bytes"
+fi
+
+# Stop boot splash; harmless if plymouth already gone.
+plymouth quit 2>/dev/null || true
+
+# Start X (chromium kiosk) in the background so rc.local can exit and
+# late-boot units (bbctrl logrotate, etc.) don't block on it. Output
+# is redirected so the journal doesn't fill up with X warnings.
+cd /home/pi
+nohup sudo -u pi startx >/var/log/onefin-x.log 2>&1 &
+disown
+
+exit 0

src/py/bbctrl/Log.py

@@ -182,4 +182,11 @@ class Log(object):
             if n == 16: os.unlink(fullpath)
             else: self._rotate(path, nextN)
 
-            os.rename(fullpath, '%s.%d' % (path, nextN))
+            # The recursive call may have unlinked or rotated this
+            # path; tolerate a missing source rather than crashing
+            # bbctrl on startup. This also tolerates concurrent
+            # logrotate runs from /etc/cron.reboot.
+            try:
+                os.rename(fullpath, '%s.%d' % (path, nextN))
+            except FileNotFoundError:
+                pass

src/py/bbctrl/Planner.py

@@ -30,7 +30,22 @@ import math
 import re
 import time
 from collections import deque
-import camotics.gplan as gplan # pylint: disable=no-name-in-module,import-error
+# camotics.gplan is heavy (loads a C++ extension that pulls in libstdc++,
+# boost::python, etc.). Defer it: bbctrl can listen on HTTP and serve
+# the UI without ever touching the planner. Lazy-load the first time
+# Planner.init() runs, which is when the user actually queues motion.
+gplan = None
+def _load_gplan():
+    global gplan
+    if gplan is None:
+        try:
+            import bbctrl.Trace as _T
+            with _T.span('imports.camotics_gplan'):
+                import camotics.gplan as _gplan # pylint: disable=no-name-in-module,import-error
+        except Exception:
+            import camotics.gplan as _gplan # pylint: disable=no-name-in-module,import-error
+        gplan = _gplan
+    return gplan
 import bbctrl.Cmd as Cmd
 from bbctrl.CommandQueue import CommandQueue
 
@@ -329,7 +344,7 @@ class Planner():
         if stop:
             self.ctrl.mach.stop()
 
-        self.planner = gplan.Planner()
+        self.planner = _load_gplan().Planner()
         self.planner.set_resolver(self._get_var_cb)
         # TODO logger is global and will not work correctly in demo mode
         self.planner.set_logger(self._log_cb, 1, 'LinePlanner:3')