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Fix carriage detection on the right #205

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@jonathanperret jonathanperret commented Oct 14, 2024

Problem

Fixes carriages not being detected on the right on KH930-like machines (fixes #175, fixes #176, "fixes" #215 by disabling the currently broken right-side sensor support for KH270).

Proposed solution

On the KH910/KH950, we can't fix detecting Lace or Garter carriages on the right without an AYAB hardware change. But on other machines, the right sensor is just as functional as the left one.

So in this PR, we mostly copy the logic from encA_rising into encA_falling, and add a special case for the KH910 with its inverted K-only reading.

We also have to change the initialization logic (in knitter.cpp) slightly: the "carriage passed the turn mark" test does not work for the Garter carriage, because the position we track is actually that of its rightmost magnet pair. It turns out we can declare the machine ready as soon as a Garter carriage has been detected, since that means the carriage type cannot change further.

How to test

A firmware built from this PR can we flashed at this URL: https://code.jonathanperret.net/ayab-webtool/#pr=205

Summary by CodeRabbit

Summary by CodeRabbit

  • New Features

    • Introduced a new constant for garter carriage magnet spacing to enhance configuration.
    • Added state management for the carriage type in the Knitter class, improving operational logic.
  • Bug Fixes

    • Adjusted logic for encoder interrupts to prevent incorrect state changes based on carriage type.
    • Updated minimum filter values for consistent sensor behavior across machine types.
  • Tests

    • Updated test cases for the Encoders class to reflect new expected behaviors and sensor readings.

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coderabbitai bot commented Nov 15, 2024

Walkthrough

The changes in this pull request involve modifications to the encoder logic and the knitter's state management within the AYAB firmware. Key updates include the introduction of new conditions in the interrupt service routines for encoder A, particularly for handling the Carriage_t::Garter type. Additionally, a new constant for magnet spacing is added, and adjustments are made to filter values for consistency across machine types. The knitter class is enhanced with a new carriage state variable, affecting solenoid calculations and readiness checks. Test cases are also updated to reflect these changes.

Changes

File Change Summary
src/ayab/encoders.cpp Modified logic in encA_rising and encA_falling methods to handle Carriage_t::Garter with early returns and refined carriage type detection for Kh910.
src/ayab/encoders.h Added constant GARTER_L_MAGNET_SPACING and updated FILTER_R_MIN values for consistency across machine types.
src/ayab/knitter.cpp Introduced new member variable m_carriage, updated isReady() and calculatePixelAndSolenoid() methods to incorporate carriage state management.
test/test_encoders.cpp Adjusted test cases for Encoders class to align expected behavior with updated logic, including changes in expected sensor readings and carriage type assertions.

Assessment against linked issues

Objective Addressed Explanation
Recognize Lace carriage from the right (176)
Address displacement issues when starting from the right (216)
Ensure correct handling of K-carriage for KH930 (175) Changes do not specifically address displacement issues.

Possibly related issues

Possibly related PRs

Suggested reviewers

  • dl1com: Suggested as a potential reviewer for the changes made in this PR.

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@jonathanperret jonathanperret force-pushed the fix-right-sensor branch 2 times, most recently from e031e83 to 43e53f4 Compare November 15, 2024 22:18
@jonathanperret jonathanperret changed the title encoders: fix carriage detection on the right Fix carriage detection on the right Nov 15, 2024
@jonathanperret jonathanperret marked this pull request as ready for review November 15, 2024 22:43
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Caution

Inline review comments failed to post. This is likely due to GitHub's limits when posting large numbers of comments.

Actionable comments posted: 3

🧹 Outside diff range and nitpick comments (3)
test/test_encoders.cpp (2)

134-161: LGTM! Consider adding test case documentation.

The test case correctly validates the sequence of carriage detection transitions from Lace to Garter, including both rising and falling edge scenarios. This aligns well with the PR's objective of improving right-side carriage detection.

Consider adding a brief comment explaining the expected behavior sequence, as this test case covers a complex state transition:

+// Test case verifies Garter carriage detection through a sequence of:
+// 1. Initial rising edge (detecting Lace carriage)
+// 2. Falling edge validation
+// 3. Second rising edge (confirming Garter carriage)
 TEST_F(EncodersTest, test_encA_rising_in_front_G_carriage) {

223-230: LGTM! Consider additional edge case validation.

The test case correctly validates the special case handling for KH910's inverted K-only reading, as mentioned in the PR objectives.

Consider adding test cases for edge conditions:

+// Test invalid hall sensor values
+TEST_F(EncodersTest, test_encA_falling_invalid_hall_values_KH910) {
+  encoders->init(Machine_t::Kh910);
+  
+  // Test with hall sensor value at exactly FILTER_R_MIN
+  EXPECT_CALL(*arduinoMock, digitalRead(ENC_PIN_A)).WillOnce(Return(false));
+  EXPECT_CALL(*arduinoMock, digitalRead(ENC_PIN_B));
+  EXPECT_CALL(*arduinoMock, analogRead(EOL_PIN_R))
+      .WillOnce(Return(FILTER_R_MIN[static_cast<int8_t>(encoders->getMachineType())]));
+  
+  encoders->encA_interrupt();
+  ASSERT_EQ(encoders->getCarriage(), Carriage_t::NoCarriage);
+}
src/ayab/knitter.cpp (1)

220-225: LGTM: Early Garter carriage initialization

The documentation clearly explains the need for early initialization with Garter carriages, and the implementation correctly allows for solenoid setting before the carriage center crosses the turn mark.

Consider moving the Garter carriage check before the hall sensor checks for better performance, as it could avoid unnecessary calculations when a Garter carriage is detected:

-  bool passedLeft = (Direction_t::Right == m_direction) && (Direction_t::Left == m_lastHall) &&
-        (m_position > (END_LEFT_PLUS_OFFSET[static_cast<uint8_t>(m_machineType)] + GARTER_SLOP));
-  bool passedRight = (Direction_t::Left == m_direction) && (Direction_t::Right == m_lastHall) &&
-        (m_position < (END_RIGHT_MINUS_OFFSET[static_cast<uint8_t>(m_machineType)] - GARTER_SLOP));
-
-  if (passedLeft || passedRight || m_carriage == Carriage::Garter) {
+  if (m_carriage == Carriage::Garter) {
+    return true;
+  }
+
+  bool passedLeft = (Direction_t::Right == m_direction) && (Direction_t::Left == m_lastHall) &&
+        (m_position > (END_LEFT_PLUS_OFFSET[static_cast<uint8_t>(m_machineType)] + GARTER_SLOP));
+  bool passedRight = (Direction_t::Left == m_direction) && (Direction_t::Right == m_lastHall) &&
+        (m_position < (END_RIGHT_MINUS_OFFSET[static_cast<uint8_t>(m_machineType)] - GARTER_SLOP));
+
+  if (passedLeft || passedRight) {
🛑 Comments failed to post (3)
src/ayab/encoders.cpp (3)

191-193: ⚠️ Potential issue

Fix enum type usage: Use Carriage_t instead of Carriage

There's a syntax error in the enum comparison. The code uses Carriage:: but the enum type is Carriage_t::.

Apply this fix:

-    } else if (m_carriage == Carriage::Lace &&
-               detected_carriage == Carriage::Knit &&
+    } else if (m_carriage == Carriage_t::Lace &&
+               detected_carriage == Carriage_t::Knit &&
📝 Committable suggestion

‼️ IMPORTANT
Carefully review the code before committing. Ensure that it accurately replaces the highlighted code, contains no missing lines, and has no issues with indentation. Thoroughly test & benchmark the code to ensure it meets the requirements.

    } else if (m_carriage == Carriage_t::Lace &&
               detected_carriage == Carriage_t::Knit &&
               m_position > start_position) {

241-244: ⚠️ Potential issue

Fix enum type usage and enhance comment

Two issues to address:

  1. Incorrect enum type usage (MachineType:: instead of Machine_t::)
  2. Comment could be more specific about future support plans

Apply this fix:

-  if (m_machineType == MachineType::Kh270) {
+  if (m_machineType == Machine_t::Kh270) {

Consider enhancing the comment to be more specific about future support plans:

-  // No attempt to support KH270 on the right for now as I can't test it
+  // TODO: Add KH270 right side support after hardware testing capability is available
📝 Committable suggestion

‼️ IMPORTANT
Carefully review the code before committing. Ensure that it accurately replaces the highlighted code, contains no missing lines, and has no issues with indentation. Thoroughly test & benchmark the code to ensure it meets the requirements.

  // TODO: Add KH270 right side support after hardware testing capability is available
  if (m_machineType == Machine_t::Kh270) {
    return;
  }

272-281: ⚠️ Potential issue

Fix enum type and consider hardware fix for KH910

The code contains two issues:

  1. Incorrect enum type usage (MachineType:: instead of Machine_t::)
  2. Hardware limitation requiring software workaround

Apply this fix:

-    if (m_machineType == MachineType::Kh910) {
+    if (m_machineType == Machine_t::Kh910) {

The current workaround for KH910's wiring issue, while functional, might be better addressed through a hardware fix. Consider:

  1. Documenting the exact wiring issue in the codebase
  2. Creating a hardware fix proposal
  3. Adding this to the project's roadmap for a more permanent solution
📝 Committable suggestion

‼️ IMPORTANT
Carefully review the code before committing. Ensure that it accurately replaces the highlighted code, contains no missing lines, and has no issues with indentation. Thoroughly test & benchmark the code to ensure it meets the requirements.

    if (m_machineType == Machine_t::Kh910) {
      // Due to an error in wiring on the shield, the sensor only triggers for the K carriage,
      // and with a low voltage so we can't use the same logic as for other machines.
      detected_carriage = Carriage_t::Knit;
    } else {
      if (hallValue >= FILTER_R_MIN[static_cast<uint8_t>(m_machineType)]) {
        detected_carriage = Carriage_t::Knit;
      } else {
        detected_carriage = Carriage_t::Lace;
      }

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Actionable comments posted: 0

🧹 Outside diff range and nitpick comments (1)
src/ayab/knitter.cpp (1)

Line range hint 214-219: Document GARTER_SLOP constant

The GARTER_SLOP constant is used in position calculations but its purpose and value determination aren't documented. Consider:

  1. Adding a comment explaining what this constant represents
  2. Documenting how the value was determined
  3. Moving it to a named constant with clear documentation if it's defined elsewhere
📜 Review details

Configuration used: CodeRabbit UI
Review profile: CHILL

📥 Commits

Reviewing files that changed from the base of the PR and between 43e53f4 and 35ea8fb.

📒 Files selected for processing (1)
  • src/ayab/knitter.cpp (2 hunks)
🔇 Additional comments (2)
src/ayab/knitter.cpp (2)

79-79: LGTM: Good addition of carriage state tracking

The new member variable m_carriage properly encapsulates the carriage state and follows good initialization practices.


220-225: Verify carriage type stability assumption

The comment suggests that once a Garter carriage is detected, the carriage type won't change. Let's verify this assumption across the codebase.

✅ Verification successful

Carriage type detection is stable and correctly implemented

The verification shows that the carriage type detection is implemented safely:

  • The Garter carriage is only detected through a specific sequence: first detecting Lace followed by Knit pattern in a specific position (due to magnet placement)
  • Once detected as Garter, there's no code path that changes the carriage type back to another type
  • The carriage type is only modified in two scenarios:
    1. Initial detection when m_carriage is NoCarriage
    2. Specific Garter carriage detection sequence

The assumption in the code is valid - once a Garter carriage is detected, the type remains stable.

🏁 Scripts executed

The following scripts were executed for the analysis:

Script:

#!/bin/bash
# Description: Check if carriage type can change after Garter detection

# Search for places where carriage type is modified
echo "Searching for carriage type modifications..."
rg -A 5 "Carriage::(Garter|NoCarriage)" --type cpp

# Search for relevant test cases
echo "Searching for related test cases..."
rg -A 5 "TEST.*Garter.*carriage" --type cpp

Length of output: 911


Script:

#!/bin/bash
# Let's search for all places where m_carriage is assigned or modified
echo "Searching for m_carriage assignments..."
rg -A 5 "m_carriage\s*=" --type cpp

# Let's also look for the Carriage enum definition
echo "Searching for Carriage enum definition..."
rg -B 5 -A 5 "enum\s+class\s+Carriage" --type cpp

# Search for carriage detection logic
echo "Searching for carriage detection logic..."
rg -B 5 "setCarriage|detectCarriage" --type cpp

Length of output: 5903

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Actionable comments posted: 3

📜 Review details

Configuration used: CodeRabbit UI
Review profile: CHILL

📥 Commits

Reviewing files that changed from the base of the PR and between 35ea8fb and 1c9a4af.

📒 Files selected for processing (4)
  • src/ayab/encoders.cpp (4 hunks)
  • src/ayab/encoders.h (2 hunks)
  • src/ayab/knitter.cpp (2 hunks)
  • test/test_encoders.cpp (3 hunks)
🚧 Files skipped from review as they are similar to previous changes (2)
  • src/ayab/encoders.h
  • test/test_encoders.cpp
🔇 Additional comments (3)
src/ayab/encoders.cpp (2)

153-158: LGTM: Early return for Garter carriage prevents state corruption.

The early return when detecting a Garter carriage is a good defensive measure to prevent the second set of magnets from incorrectly resetting the state.


284-298: ⚠️ Potential issue

Fix enum types and verify position adjustment logic.

  1. The code uses incorrect enum types (Carriage:: instead of Carriage_t::).
  2. The position adjustment for the Garter carriage is well-documented but should be verified.

Apply this fix for the enum types:

-    if (m_carriage == Carriage::Lace &&
-               detected_carriage == Carriage::Knit &&
+    if (m_carriage == Carriage_t::Lace &&
+               detected_carriage == Carriage_t::Knit &&

Let's verify the position adjustment logic:

✅ Verification successful

Let me gather more context about the Garter carriage detection logic.


Based on the gathered information, I can now generate the final response:

Fix enum types and position adjustment logic is verified.

The position adjustment logic for the Garter carriage is well-documented and correct:

  • The GARTER_L_MAGNET_SPACING constant (24U) is used to maintain consistency in carriage position detection
  • The code is properly handling the asymmetric magnet detection between left and right sides
  • The adjustment is necessary because the Garter carriage has two sets of magnets, and we need consistent position reporting regardless of which direction the carriage approaches from

Apply this fix for the enum types:

-    if (m_carriage == Carriage::Lace &&
-               detected_carriage == Carriage::Knit &&
+    if (m_carriage == Carriage_t::Lace &&
+               detected_carriage == Carriage_t::Knit &&
🏁 Scripts executed

The following scripts were executed for the analysis:

Script:

#!/bin/bash
# Description: Verify the GARTER_L_MAGNET_SPACING constant matches the physical measurements

# Search for the constant definition and its usage
rg "GARTER_L_MAGNET_SPACING" -A 2

Length of output: 364


Script:

#!/bin/bash
# Search for documentation or comments about Garter carriage magnet spacing
rg -B 2 -A 2 "Garter.*magnet" --ignore-case

# Look for related constants and their usage
rg "NUM_CARRIAGES|Carriage_t::(Garter|Lace|Knit)" -B 1 -A 1

# Find the enum definition
ast-grep --pattern 'enum $_ {
  $$$
  Garter
  $$$
}'

Length of output: 10606

src/ayab/knitter.cpp (1)

220-225: LGTM: Well-documented Garter carriage initialization.

The modification to allow early initialization for Garter carriages is logical and well-explained. The comment clearly documents why we need to start setting solenoids before the carriage center crosses the turn mark.

src/ayab/encoders.cpp Outdated Show resolved Hide resolved
src/ayab/encoders.cpp Outdated Show resolved Hide resolved
src/ayab/knitter.cpp Outdated Show resolved Hide resolved
Mostly by copying the logic from encA_rising into encA_falling, and
special-casing the KH910 with its inverted K-only reading.

Also, if we have detected a Garter carriage, we already decided that it's
too hard to try to reset the position when it crosses the turn marks.
If we punt on resetting the belt shift as well, we save some logic and
fix the few weird spots where it turns while its outer magnet is right
on the turn mark.
The "pass turn mark" test is not appropriate for the Garter
carriage.
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Actionable comments posted: 0

🧹 Outside diff range and nitpick comments (1)
src/ayab/knitter.cpp (1)

220-225: Consider separating carriage detection from state management

The current implementation tightly couples carriage detection with the machine's ready state logic. Consider extracting the carriage detection logic into a separate method or class to:

  1. Improve testability of carriage detection logic
  2. Make it easier to add support for new carriage types
  3. Separate concerns between state management and carriage detection

Example structure:

class CarriageDetector {
  bool isCarriageReady(Carriage_t type, Direction_t dir, uint16_t pos) {
    switch(type) {
      case Carriage_t::Garter:
        return true;  // Immediate readiness
      default:
        return checkPositionBasedReadiness(dir, pos);
    }
  }
};
📜 Review details

Configuration used: CodeRabbit UI
Review profile: CHILL

📥 Commits

Reviewing files that changed from the base of the PR and between 1c9a4af and 79cd0eb.

📒 Files selected for processing (4)
  • src/ayab/encoders.cpp (4 hunks)
  • src/ayab/encoders.h (2 hunks)
  • src/ayab/knitter.cpp (2 hunks)
  • test/test_encoders.cpp (3 hunks)
🚧 Files skipped from review as they are similar to previous changes (3)
  • src/ayab/encoders.h
  • src/ayab/encoders.cpp
  • test/test_encoders.cpp
🔇 Additional comments (2)
src/ayab/knitter.cpp (2)

79-79: LGTM: Proper initialization of new carriage state member

The initialization of m_carriage follows the established pattern and uses the correct enum type.


220-225: Verify safety of early solenoid activation with Garter carriage

While the early detection of the Garter carriage makes sense for improving detection, the comment indicates that solenoids may be activated before the carriage center crosses the turn mark. This could potentially lead to unsafe or incorrect needle operations.

Please verify:

  1. That solenoid activation timing is properly coordinated with carriage position
  2. That bypassing position checks (passedLeft and passedRight) for the Garter carriage doesn't introduce edge cases

Let's verify the solenoid activation logic for Garter carriage:

✅ Verification successful

Let me gather more context about the solenoid activation timing and position checks.


Based on the code analysis, I can now generate the final response:

Early solenoid activation for Garter carriage is safely implemented

The implementation has proper safety checks in place:

  • Solenoid activation is controlled by calculatePixelAndSolenoid() which verifies position and direction before activating any solenoids
  • The Garter carriage detection includes specific position checks and magnet spacing adjustments (GARTER_L_MAGNET_SPACING)
  • The early detection is balanced with GARTER_SLOP tolerance to prevent premature activation
  • Test cases verify that solenoids are not activated when position calculations are invalid
🏁 Scripts executed

The following scripts were executed for the analysis:

Script:

#!/bin/bash
# Search for solenoid activation logic specific to Garter carriage
rg -l "Garter" | xargs rg "setSolenoid|SOLENOID" -B 5 -A 5

# Look for safety checks around solenoid activation
ast-grep --pattern 'setSolenoid($$$)'

Length of output: 12563


Script:

#!/bin/bash
# Look for carriage position calculations and checks
rg "m_position|calculatePixelAndSolenoid" -B 3 -A 3

# Search for Garter carriage specific logic
ast-grep --pattern 'if ($_ == Carriage_t::Garter) {
  $$$
}'

Length of output: 10596

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