Henrik Muehe 53f26b0be8 feat: integrate W axis as virtual A axis through gplan
Big-bang refactor of the W-axis integration. The auxcnc ESP stepper
is now exposed to the bbctrl planner (camotics gplan) as a virtual
A axis with no AVR motor mapping. gplan parses gcode for A natively,
applies soft limits, units, accel ramping and S-curve trajectories.
Line blocks with A motion are intercepted in Planner.__encode and
forked to the ESP via ExternalAxis on a worker thread; the residual
XYZ motion goes to the AVR as before.

This replaces the previous (MSG,HOOK:aux:N) side-channel: gcode
authors now write G1 A50 F1000 (or G28 A0 to home) and the planner
handles it the same way it handles X/Y/Z.

## Architecture

The AVR has 4 motor channels (0-3, all assigned to X/Y/Y/Z on
Onefinity). Looking at the AVR source, an axis with no motor
mapping is fully accepted: line blocks with that axis target update
ex.position[axis] in exec.c, but no motor steps because
motor_get_axis(motor)==axis returns -1. The AVR reports 'p' for
all 6 axes regardless. So we expose A to State as a synthetic
motor (index 4, host-only), populated from aux.json with full
kinematic config (vm/am/jm/tn/tm). State.find_motor and the
snapshot projection now walk 0..4. gplan sees A as a real axis.

## New module: ExternalAxis

  - Registers synthetic motor 4 with vm/am/jm/tn/tm so
    State.find_motor('a') returns 4 and gplan picks up
    soft limits + kinematics.
  - Worker thread drains a target queue so ESP RPCs (which can
    take seconds) never block the bbctrl ioloop.
  - execute_to_mm: synchronous, used by HTTP endpoints.
  - enqueue_target_mm: non-blocking, used by Planner.__encode.
  - home(): runs ESP cycle, syncs <axis>p and <axis>_homed.
  - abort(): drains queue.

## Planner

  - __encode splits external-axis target out of line blocks.
  - Pure A move -> emits id-sync only (planner advances cleanly).
  - Mixed XYZ + A -> AVR runs XYZ trapezoid concurrent with the
    ESP move (v1 accepts the slight desync; users wanting strict
    sequencing put A on its own gcode line).
  - _<axis>_homed for the synthetic motor mirrors into State only.
  - Planner.reset drains the worker queue and forces resync.

## Mach

  - Mach.home(axis='a') routes through ext.home() instead of the
    standard G28.2/G38.6 latch sequence (which doesn't apply to an
    ESP-driven axis), then issues G28.3 a<home> to sync gplan.
  - Mach.unhome strips the AVR path for A.
  - Mach.stop / E-stop drain the external-axis worker queue.
  - Mach.jog strips A so the AVR doesn't see it (continuous-rate
    jogging not supported on ESP yet; use /api/aux/jog instead).

## State

  - find_motor walks 0..4 (synthetic motor 4 lives in vars).
  - snapshot projection includes motor 4 so 4tn -> a_tn etc.
  - get_axis_vector picks up motor-4 values without changes.

## AuxAxis

  - Adds set_state_observer hook so ExternalAxis sees homed-flag
    changes after homing/boot-banner.
  - DEFAULTS now include axis_letter, max_velocity_m_per_min,
    max_accel_km_per_min2, max_jerk_km_per_min3 in user-facing
    motor-config units (m/min, km/min^2, km/min^3) matching the
    onefinity per-motor convention.

## AuxPreprocessor

  - Drops W-token rewriting entirely. M100..M103 ATC mapping kept.
  - W tokens in legacy gcode now warn (once per file) instead of
    being rewritten. Migration: replace W with A.

## Hooks

  - aux/aux_rel/aux_setzero hooks retired. aux_home kept as a
    legacy alias routing to ext.home() for older preprocessed
    gcode. ATC hooks (droptool/grabtool/release/clamp) unchanged.
  - E-stop now drains the external-axis worker queue.

## Web.py

  - /api/aux/{home,jog,move} now route through ExternalAxis when
    available so DRO and gplan position stay in sync.

## UI (axis-vars.js + control-view.pug)

  - _get_motor_id and _check_is_enabled fall back to motor index 4
    so the standard A column in the DRO renders state for the
    ESP-driven axis (with full offset / set-position / per-axis
    home support).
  - Legacy W row is gated on !a.enabled - shown only for installs
    that haven't migrated.
  - WAxisSettings.svelte exposes the new max_velocity_m_per_min /
    max_accel_km_per_min2 / max_jerk_km_per_min3 fields and an
    axis_letter selector for picking A/B/C.

## Open follow-ups (validate on hardware)

  - Q1: gplan soft-limit enforcement for A with min/max set.
    Easy smoke test: max_w=50, MDI G1 A100, expect rejection.
  - Q2: AVR behaviour with a target dict containing A values for
    a motorless axis. Read of exec.c suggests it's safe; needs a
    smoke test (no motor faults, no unexpected step counts).
  - Q3: pause/resume mid-A-move semantics. ESP doesn't honour
    bbctrl pauses; ext.abort drains the queue but a move-in-flight
    runs to completion. Acceptable for v1; v2 could add a synced
    pause.
2026-05-02 17:17:20 +02:00
2026-04-30 11:17:03 +02:00
2026-04-30 21:33:48 +02:00
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2020-08-27 23:20:27 -04:00
2025-09-21 01:57:17 +05:30
2025-09-21 01:57:17 +05:30
2020-08-27 23:20:27 -04:00
2020-08-27 23:20:27 -04:00

OneFinity CNC Controller Firmware (W-axis fork)

This is the OneFinity / Buildbotics bbctrl firmware with a virtual W axis driven by an auxcnc ESP32 over USB serial. See docs/AUX_W_AXIS.md for the design and config.

Layout

src/avr/        AVR firmware (motion controller, AtxMega)
src/boot/       AVR bootloader
src/bbserial/   Linux kernel module for the bbserial driver
src/py/bbctrl/  Python control daemon (Tornado + websockets)
src/js/         Vue.js UI (legacy)
src/svelte-components/  Newer Svelte UI for dialogs and settings
src/pug/        Pug templates compiled into build/http/index.html
src/resources/  Static assets and config templates
scripts/        Install / update / RPi build helpers
docs/           Architecture, dev setup, W-axis docs

Build & flash (quick path, macOS or Linux)

The full build (make) requires avr-gcc, but the controller and UI only depend on the Python + web parts. If you're shipping a UI/Python change you don't need the AVR toolchain.

Prerequisites

  • Node.js (any recent LTS) with npm
  • Python 3 with setuptools
  • npm install once at the project root (this is wired into the node_modules Make target, but on a fresh checkout it's clearer to do it explicitly)
npm install
(cd src/svelte-components && npm install)

macOS gotcha: esbuild platform pin

The Pi build leaves node_modules/esbuild pinned to linux-arm64, which won't run on Darwin. If npm run build inside src/svelte-components complains about esbuild, reinstall it for the host:

cd src/svelte-components
rm -rf node_modules/esbuild
npm install esbuild@0.14.49 --no-save

(Use the version that matches package-lock.json.)

Build the web UI + Python sdist

# Build the Svelte components
(cd src/svelte-components && npm run build)

# Render pug templates and copy assets into build/http
make all          # AVR step will fail without avr-gcc; safe to ignore
                  # if you didn't change anything under src/avr or src/boot

# Package
./setup.py sdist
ls dist/bbctrl-*.tar.bz2

make pkg is the canonical target but it tries to build AVR first. On hosts without avr-gcc, run the steps above directly.

If bbctrl-*.tar.bz2 is missing src/bbserial/bbserial.ko, copy the prebuilt .ko from a previous official release into src/bbserial/ before running setup.py sdist (the install script on the controller just installs the existing module if a newer one isn't shipped).

Flash to a controller

curl -X PUT -H "Content-Type: multipart/form-data" \
  -F "firmware=@dist/bbctrl-1.6.7.tar.bz2" \
  -F "password=onefinity" \
  http://onefinity.local/api/firmware/update

…or use the Make target:

make update HOST=onefinity.local PASSWORD=onefinity

The controller stops bbctrl, untars the package, runs scripts/install.sh, and brings the service back up. Total downtime is ~30-45s. Watch progress at http://<host>/ (you'll get 404s while bbctrl restarts, then the new UI).

Verify the flash

curl -s http://onefinity.local/ | grep -c "OneFinity"
curl -s http://onefinity.local/api/aux/status   # if W axis is enabled

Build & flash (full path, Debian/Linux)

For AVR + GPlan rebuilds, see docs/development.md. That path uses qemu + chroot to cross-compile gplan for ARM and needs the gcc-avr / avr-libc toolchain.

W axis (auxcnc)

This fork adds a virtual W axis. See docs/AUX_W_AXIS.md for:

  • G-code surface (G28 W0, G1 W25, etc.)
  • The G-code preprocessor and hook architecture
  • aux.json keys
  • REST API (/api/aux/*)
  • UI surface (jog row in Control, settings panel in Settings)
  • Edge cases (ESP reboot mid-job, limit closed at home start, …)
Description
Onefinity CNC controller firmware (fork of OneFinityCNC/onefinity-firmware) with W axis (auxcnc) integration, hooks, build/flash docs, and V09 UX redesign.
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