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Author SHA1 Message Date
Henrik Muehe
214de86bdf Z-A coupling: drop active jog/MDI auto-coordination, keep refuse-only check 
The active rewriter for jogs/MDI didn't help anyway because the
continuous-jog buttons send rate-based /api/jog commands to the AVR
and bypass the planner+MDI path entirely. Rather than build out
continuous-jog coupling on the ESP firmware or fake it with browser
ticks, simplify back to:

  * Runtime check (Planner.__encode + ExternalAxis motion entry
    points) refuses any move that would worsen the Z-A gap. Already
    improvement-aware so X/Y jogs and Z-up/A-down recoveries pass.
  * File preprocessor (AuxPreprocessor) injects pre-position A
    moves into uploaded gcode so well-formed programs run without
    operator intervention.

Operator workflow: jog freely down to the safe band; if you need to
go deeper, lower A first (aux jog mm) or use a step-jog MDI like
'G91 G0 Z-10 A-10' that includes the A delta. Programs do the right
thing on their own.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
be3a53e518 AuxAxis: push home_preclear_mm via HOMECFG 
Tells the auxcnc ESP how far (in steps) to back off if HOME is
invoked while the limit switch is already tripped. The ESP now
hard-fails instead of zeroing blindly when the switch stays active
after the preclear move. Default 10 mm; set home_preclear_mm=0 to
disable the preclear and revert to immediate failure.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
b9f7bbeec9 Z-A coupling: auto-coordinate A on jogs and MDI 
Match the file-preprocessor behaviour for live operator input. When a
Z-down jog or MDI line would push (A-Z) above the safe band, append
the matching A delta to the same line so the planner runs Z and A
together. Same direction-aware refusal: only error when the operator
explicitly asks A to move *up* (delta > 0) past the bound, or when
the required A would violate A's soft minimum.

Implementation:
  * ExternalAxis.coordinate_mdi rewrites a multi-line MDI burst,
    tracking G90/G91 modal across lines (jogs always emit
    M70/G91/G0/M72; standard MDI defaults to G90). Z and A targets
    are computed in machine coords using offset_z and offset_a so
    the work-coord A token we emit is consistent with the operator's
    frame.
  * The 'A0' the jog UI emits for axes that aren't moving is treated
    as 'no A intent' (G91 delta of zero) and freely overridden.
  * Hooked into Mach.mdi after the existing ATC rewrite. On
    ExternalAxisError the burst is dropped with a user message; the
    planner check downstream still fires as defense in depth.
  * Planner.__encode also catches ExternalAxisError now (vs
    bricking on uncaught) - logs to the operator messages list and
    halts the cycle cleanly so subsequent jogs work.
  * check_coupling itself is now improvement-aware: only refuses
    moves that worsen an existing violation. Pure XY jogs and
    Z-up/A-down recovery moves pass even when (A-Z) is currently
    above the bound.

Tested locally with synthetic MDI: small Z jog within band, Z jog
across the boundary (auto-injects A delta), G90 MDI G0 Z-50
(appends A106), explicit A-lift while Z deep (refuses), pure XY
jog (unchanged), G91 A-down (unchanged), G90 G0 A0 with
offset_a=134 (refuses as lift to home).
 2026-05-03 15:10:26 +02:00
Henrik Muehe
ec40429dec Z-A coupling interlock: prevent collision between Z and A tools 
The auxiliary A axis carries a tool that hangs below the Z spindle.
Beyond a small Z descent the two physically collide unless A drops
with Z. Enforce in machine coords:

    A_machine - Z_machine <= K
    K = (A_home_mm - z_home_mm) + couple_z_clearance_mm

With our setup K = (134 - 0) + 22 = 156. At rest A=134 Z=0, A-Z=134
which is fine. Z can descend 22mm before the rule starts forcing A
down with it.

Two complementary layers:

(1) AuxPreprocessor injection (auto-fix uploaded files)
    Tracks modal Z, A and distance mode (G90/G91) while scanning the
    file. When a line would put A above Z by more than the clearance
    we emit a 'G0 A<safe>' BEFORE the line so A is already at the
    safe position when Z descends. Endpoint check is sufficient
    because Z moves monotonically along a single line.

    Errors are raised (not silently auto-fixed) when:
      - the line lifts A above the safe band while Z stays put
        (would require auto-injecting a Z-up which could swing
        through a fixture)
      - the line endpoint targets an A above the safe band

    G91 disables injection with a one-shot warning; the runtime
    check still applies.

(2) Runtime check (ExternalAxis.check_coupling)
    Single source of truth for live motion. Hooked into:
      * Planner.__encode for every line block (covers MDI and
        running programs - gplan emits machine-coord targets)
      * ExternalAxis.execute_to_mm/enqueue_target_mm/enqueue_line
        for direct A motion (covers UI jog/move and planner-A
        dispatch)
    Raises ExternalAxisError on violation; gplan and the API both
    surface the message. Skipped when coupling is disabled or the
    axis isn't homed (mirrors the soft-limit gate).

    Continuous Z jog from the AVR is not gated - it's an active
    operator action without a pre-known endpoint. Operator-driven
    over-travel during continuous jog will be caught by the next
    MDI/file-load attempt.

Configuration in aux.json:
    couple_z_enabled        bool   default true (per agreed setup)
    couple_z_clearance_mm   float  default 22.0
    z_home_mm               float  default 0.0

Surfaced in the new Z-A Coupling section of the A Axis settings
page with a description of the rule. Existing aux.json files get
the new keys via the merged-defaults path on read.

Tested locally with synthetic gcode covering Z descent, combined
moves, A lift while Z deep, G92 reset, G91 mode, and combined
Z+A target violations.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
789ca4871b docs: A axis architecture (renamed from W) + README section 
- Move docs/AUX_W_AXIS.md to docs/AUX_A_AXIS.md and rebadge W -> A
  throughout, with a header note pointing at ExternalAxis as the
  current implementation.
- README: A-axis fork heading, link to AUX_A_AXIS.md, /api/aux/status
  in verify-flash, small comment in scripts/deploy/local.sh.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
d65abac0d5 Config: idempotent macro file rename W -> A 
The auxiliary stepper used to be exposed as a W axis. After the
gplan integration it is exposed as A. Migrate persisted macro
config on every load:
  w_down.nc -> a_down.nc
  w_up.nc   -> a_up.nc
  'W Down'  -> 'A Down'
  'W Up'    -> 'A Up'

Idempotent so a stale in-memory copy can never reintroduce the old
names.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
6bc1e4feea UI: A axis surface (DRO row, jog, Home A, settings page) 
Front-end side of the gplan-integrated A axis (B3).

- a-axis-view.{js,pug}: dedicated settings page that mounts the
  AAxisSettings Svelte component and lives at #a-axis in the V09
  settings rail.
- AAxisSettings.svelte: aux.json-backed form (axis letter, port,
  homing direction, soft limits, ATC pin map, etc.) with master
  Save integration via 'onefin:save-all'.
- main.ts + SettingsView.svelte: register AAxisSettings in the
  Svelte component map; SettingsView no longer embeds the W axis
  fieldset.
- settings-shell-view: 'A Axis' rail entry; route to a-axis-view.
- app.js: extend settings family to include 'a-axis'; broadcast
  onefin:save-all from the master Save button.
- control-view: Home All button waits for the gantry cycle to
  finish before firing Home A on a non-virtual setup; A jog
  buttons; aux_jog/aux_home/aux_jog_incr methods.
- control-view.pug: A row in the DRO (with set-position + zero +
  home actions), A- / A+ tiles in the jog grid (gated on
  w.enabled || a.enabled), legacy W row kept for installs that
  haven't migrated to the gplan integration.
- style.styl: dro-axis.axis-w color.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
3cab165d80 ATC: M100..M103 preprocessor + Mach MDI rewrite + hook handlers 
ATC pneumatics in g-code (drop tool / grab tool / release clamp /
engage clamp) are expressed as M100..M103. AuxPreprocessor rewrites
those into (MSG,HOOK:droptool:) etc on file upload + on planner
load + on MDI input, so the Hooks layer (B1) can dispatch them via
registered ATC handlers in Ctrl.

- AuxPreprocessor.py: regex-based file rewriter, idempotent.
- FileHandler: invoke preprocessor on every upload.
- Planner.init: also re-preprocess on load (catches files written
  before this version).
- Mach.mdi: same rewrite for ad-hoc MDI input so M101 typed at the
  console produces a HOOK message.
- Ctrl: register the four ATC hooks (droptool/grabtool/release/clamp)
  with block_unpause + auto_resume so programs using them pause at
  the right point and resume cleanly. aux_home retained as a legacy
  alias for older preprocessed files.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
6d4c51bd49 ExternalAxis: virtual A axis through gplan, mirrored on the ESP 
ExternalAxis exposes the auxcnc-driven ESP stepper as motor 4 (a
synthetic, host-only motor that gplan sees but the AVR doesn't). The
result is a virtual A axis that is fully integrated with the planner:
G1 A25 F1500 schedules a coordinated S-curve and the ESP runs the
exact same 7-segment trajectory the AVR would have run if A were a
real motor.

- ExternalAxis.py: synthetic-motor state, S-curve LINE block forward
  to the ESP, soft-limit enforcement, option-(b) homing (user A=0
  at the home limit).
- State: walk motors 0..4 in find_motor; clear both homed and h on
  reset; expose synthetic motor vars.
- axis-vars.js: motor-4 guard so the JS computed axis bindings don't
  throw when motor 4 has no entry in config.motors; resolve motor_id
  for the synthetic axis by scanning state['4an'].
- Ctrl: instantiate ExternalAxis after AuxAxis, share the axis_letter
  setting, wire AuxAxis state observer.
- Web: route /api/aux/{home,jog,move} through ExternalAxis when it
  is enabled so the DRO and synthetic-motor flags stay in sync.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
32bf65934b AuxAxis: ESP32-driven external stepper (auxcnc) 
bbctrl.AuxAxis manages a stepper driven by an auxcnc-style ESP32
over /dev/ttyUSB0 (or whichever serial port). Persistent config in
aux.json; UI talks to it via /api/aux/* endpoints.

- AuxAxis: serial framing, position tracking, soft-limit enforcement,
  homing state machine, ATC pneumatic control (M100..M103 wrappers).
- Ctrl: instantiate self.aux alongside the other subsystems and
  close it during shutdown.
- Web: handlers for /api/aux/{config,status,home,abort,jog,move,set-zero}.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
6185c65afa Hooks: ATC IPC layer between gcode preprocessor and runtime 
Adds bbctrl.Hooks: a small dispatch layer for HOOK:<event>:<data>
messages embedded in g-code as (MSG,HOOK:droptool:) etc. Hooks can
block the unpause until the registered callback completes and
auto-resume after.

- bbctrl.Hooks: registry, fire, dispatch_hook_message, persistent
  config in hooks.json, REST surface (/api/hooks, /api/hooks/save,
  /api/hooks/status, /api/hooks/fire/<event>).
- Ctrl: instantiate self.hooks alongside the other subsystems.
- Planner._add_message: when a (MSG,...) line is HOOK:<event>:<data>,
  route it through ctrl.hooks instead of state.messages so it never
  surfaces as a UI popup and dispatch is immediate (state.messages
  has a 250ms debounce).
- Web: handlers for the /api/hooks routes.
 2026-05-03 15:10:26 +02:00
Henrik Muehe
2b949c4f00 docs: AGENTS.md - branch model and where-does-it-go guide 2026-05-03 15:10:25 +02:00
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# Onefinity firmware — agent guidelines
## Branch model
This fork lives on **two long-lived branches**:
- **`master`** — public-facing fork. General-use upgrades on top of
upstream OneFinity firmware: V09 UX redesign, Font Awesome 6, faster
cold boot, macOS dev/deploy tooling, build & flash docs, SD-card
backup, `/api/diag/timing`, kiosk/tablet polish, and assorted
bug-fixes. **No A-axis, ATC, hooks, or auxcnc/ESP content.** Aim for
changes that benefit any Onefinity owner.
- **`esp-a-axis`** — bespoke shop branch. Stacks on top of `master`
and adds everything specific to the auxcnc-ESP-driven A axis and
the ATC: `Hooks` (ATC IPC), `AuxAxis` (ESP serial driver),
`ExternalAxis` (virtual A through gplan), `AuxPreprocessor` (M100-M103),
Z-A coupling interlock, the A-axis UI surface, and the
`/api/aux/*` endpoints.
Upstream:
- `upstream` → `https://github.com/OneFinityCNC/onefinity-firmware.git`
- `origin` → Gitea (`https://gitea.home.muehe.org/muehe/onefinity-firmware.git`)
`origin/pre-split-backup` is a tag preserving the pre-split master
tip. Keep it indefinitely until further notice.
## Where does a change go?
| Change | Branch |
|---|---|
| UI polish, theme, layout that any user benefits from | `master` |
| Build / install / boot performance | `master` |
| Diagnostics, logging, generic Python / Tornado fixes | `master` |
| Anything that touches `AuxAxis`, `ExternalAxis`, `Hooks`, `AuxPreprocessor` | `esp-a-axis` |
| Anything mentioning the auxcnc ESP, `/dev/ttyUSB0`, the M100-M103 ATC pneumatics, or motor index 4 | `esp-a-axis` |
| Z-A coupling interlock, ATC tool change sequencing | `esp-a-axis` |
| A-axis UI (DRO row, jog tile, settings page, A-axis routes) | `esp-a-axis` |
| W → A renames or aux.json migrations | `esp-a-axis` |
When in doubt: ask "would this be useful on a stock Onefinity with no
ESP attached?" If yes → `master`. If no → `esp-a-axis`.
## Workflow
```bash
# Day-to-day shop / hardware work (default)
git checkout esp-a-axis
# … do work, commit …
git push origin esp-a-axis
# Generic improvement to master
git checkout master
# … do work, commit …
git push origin master
# After landing on master, replay esp-a-axis on top
git checkout esp-a-axis
git rebase master
git push --force-with-lease origin esp-a-axis
```
If a change accidentally lands on `master` but is bespoke (touches
the file table above), move it: `git reset --hard <prev>` on master,
cherry-pick onto `esp-a-axis`, force-push master.
## Deploy
- `./deploy.sh local` — UI bundle on `localhost:8770` (tmux session
`onefin-local`). No controller backend; A-axis row stays hidden.
- `./deploy.sh hardware` — rsync to the Pi over SSH, restart
`bbctrl.service`. Use the `esp-a-axis` branch on the shop Pi.
- `./deploy.sh prod` — bundle a release tarball.
See `.pi/BUILD.md` for the full build / flash / cross-compile flow.
## Commit before ending a turn; push after significant changes.