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connection_manager.py 63 KB

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  1. import threading
  2. import time
  3. import logging
  4. import serial
  5. import serial.tools.list_ports
  6. import websocket
  7. import asyncio
  8. import os
  9. from modules.core import pattern_manager
  10. from modules.core.state import state
  11. from modules.led.led_interface import LEDInterface
  12. from modules.led.idle_timeout_manager import idle_timeout_manager
  13. logger = logging.getLogger(__name__)
  14. IGNORE_PORTS = ['/dev/cu.debug-console', '/dev/cu.Bluetooth-Incoming-Port']
  15. # Ports to deprioritize during auto-connect (shown in UI but not auto-selected)
  16. DEPRIORITIZED_PORTS = ['/dev/ttyS0']
  17. async def _check_table_is_idle() -> bool:
  18. """Helper function to check if table is idle."""
  19. return not state.current_playing_file or state.pause_requested
  20. def _start_idle_led_timeout():
  21. """Start idle LED timeout if enabled."""
  22. if not state.dw_led_idle_timeout_enabled or state.dw_led_idle_timeout_minutes <= 0:
  23. return
  24. logger.debug(f"Starting idle LED timeout: {state.dw_led_idle_timeout_minutes} minutes")
  25. idle_timeout_manager.start_idle_timeout(
  26. timeout_minutes=state.dw_led_idle_timeout_minutes,
  27. state=state,
  28. check_idle_callback=_check_table_is_idle
  29. )
  30. ###############################################################################
  31. # Connection Abstraction
  32. ###############################################################################
  33. class BaseConnection:
  34. """Abstract base class for a connection."""
  35. def send(self, data: str) -> None:
  36. raise NotImplementedError
  37. def flush(self) -> None:
  38. raise NotImplementedError
  39. def readline(self) -> str:
  40. raise NotImplementedError
  41. def in_waiting(self) -> int:
  42. raise NotImplementedError
  43. def is_connected(self) -> bool:
  44. raise NotImplementedError
  45. def close(self) -> None:
  46. raise NotImplementedError
  47. ###############################################################################
  48. # Serial Connection Implementation
  49. ###############################################################################
  50. class SerialConnection(BaseConnection):
  51. def __init__(self, port: str, baudrate: int = 115200, timeout: int = 2):
  52. self.port = port
  53. self.baudrate = baudrate
  54. self.timeout = timeout
  55. self.lock = threading.RLock()
  56. logger.info(f'Connecting to Serial port {port}')
  57. self.ser = serial.Serial(port, baudrate, timeout=timeout)
  58. state.port = port
  59. logger.info(f'Connected to Serial port {port}')
  60. def send(self, data: str) -> None:
  61. with self.lock:
  62. self.ser.write(data.encode())
  63. self.ser.flush()
  64. def flush(self) -> None:
  65. with self.lock:
  66. self.ser.flush()
  67. def readline(self) -> str:
  68. with self.lock:
  69. return self.ser.readline().decode().strip()
  70. def in_waiting(self) -> int:
  71. with self.lock:
  72. return self.ser.in_waiting
  73. def reset_input_buffer(self) -> None:
  74. """Clear any stale data from the serial input buffer."""
  75. with self.lock:
  76. if self.ser and self.ser.is_open:
  77. self.ser.reset_input_buffer()
  78. def is_connected(self) -> bool:
  79. return self.ser is not None and self.ser.is_open
  80. def close(self) -> None:
  81. # Save current state synchronously first (critical for position persistence)
  82. try:
  83. state.save()
  84. except Exception as e:
  85. logger.error(f"Error saving state on close: {e}")
  86. # Schedule async position update if event loop exists, otherwise skip
  87. # This avoids creating nested event loops which causes RuntimeError
  88. try:
  89. loop = asyncio.get_running_loop()
  90. # We're in async context - schedule as task (fire-and-forget)
  91. asyncio.create_task(update_machine_position())
  92. logger.debug("Scheduled async machine position update")
  93. except RuntimeError:
  94. # No running event loop - we're in sync context
  95. # Position was already saved above, skip async update to avoid nested loop
  96. logger.debug("No event loop running, skipping async position update")
  97. with self.lock:
  98. if self.ser.is_open:
  99. self.ser.close()
  100. ###############################################################################
  101. # WebSocket Connection Implementation
  102. ###############################################################################
  103. class WebSocketConnection(BaseConnection):
  104. def __init__(self, url: str, timeout: int = 5):
  105. self.url = url
  106. self.timeout = timeout
  107. self.lock = threading.RLock()
  108. self.ws = None
  109. self.connect()
  110. def connect(self):
  111. logger.info(f'Connecting to Websocket {self.url}')
  112. self.ws = websocket.create_connection(self.url, timeout=self.timeout)
  113. state.port = self.url
  114. logger.info(f'Connected to Websocket {self.url}')
  115. def send(self, data: str) -> None:
  116. with self.lock:
  117. self.ws.send(data)
  118. def flush(self) -> None:
  119. # WebSocket sends immediately; nothing to flush.
  120. pass
  121. def readline(self) -> str:
  122. with self.lock:
  123. data = self.ws.recv()
  124. # Decode bytes to string if necessary
  125. if isinstance(data, bytes):
  126. data = data.decode('utf-8')
  127. return data.strip()
  128. def in_waiting(self) -> int:
  129. return 0 # Not applicable for WebSocket
  130. def is_connected(self) -> bool:
  131. return self.ws is not None
  132. def close(self) -> None:
  133. # Save current state synchronously first (critical for position persistence)
  134. try:
  135. state.save()
  136. except Exception as e:
  137. logger.error(f"Error saving state on close: {e}")
  138. # Schedule async position update if event loop exists, otherwise skip
  139. # This avoids creating nested event loops which causes RuntimeError
  140. try:
  141. loop = asyncio.get_running_loop()
  142. # We're in async context - schedule as task (fire-and-forget)
  143. asyncio.create_task(update_machine_position())
  144. logger.debug("Scheduled async machine position update")
  145. except RuntimeError:
  146. # No running event loop - we're in sync context
  147. # Position was already saved above, skip async update to avoid nested loop
  148. logger.debug("No event loop running, skipping async position update")
  149. with self.lock:
  150. if self.ws:
  151. self.ws.close()
  152. def list_serial_ports():
  153. """Return a list of available serial ports."""
  154. ports = serial.tools.list_ports.comports()
  155. available_ports = [port.device for port in ports if port.device not in IGNORE_PORTS]
  156. logger.debug(f"Available serial ports: {available_ports}")
  157. return available_ports
  158. def device_init(homing=True):
  159. # IMPORTANT: Query machine position BEFORE reset to determine if homing is needed
  160. # If machine wasn't power cycled, it retains position and we can skip homing
  161. # Reset ($Bye) zeroes position counters, so we must check BEFORE reset
  162. try:
  163. if get_machine_steps():
  164. logger.info(f"x_steps_per_mm: {state.x_steps_per_mm}, y_steps_per_mm: {state.y_steps_per_mm}, gear_ratio: {state.gear_ratio}")
  165. else:
  166. logger.fatal("Failed to get machine steps")
  167. state.conn.close()
  168. return False
  169. except:
  170. logger.fatal("Not GRBL firmware")
  171. state.conn.close()
  172. return False
  173. # Check machine position BEFORE reset to decide if homing is needed
  174. machine_x, machine_y = get_machine_position()
  175. needs_homing = False
  176. if machine_x != state.machine_x or machine_y != state.machine_y:
  177. logger.info(f'Machine position mismatch - machine: ({machine_x}, {machine_y}), saved: ({state.machine_x}, {state.machine_y})')
  178. needs_homing = homing
  179. else:
  180. logger.info('Machine position matches saved state, skipping home')
  181. logger.info(f'Theta: {state.current_theta}, rho: {state.current_rho}')
  182. logger.info(f'Position: ({machine_x}, {machine_y})')
  183. # Now perform soft reset to ensure controller is in a clean state
  184. # This clears any pending commands and resets position counters to 0
  185. logger.info("Performing soft reset for clean controller state...")
  186. perform_soft_reset_sync()
  187. time.sleep(1) # Extra stabilization after controller restart
  188. # Reset work coordinate offsets for a clean start
  189. # This ensures we're using work coordinates (G54) starting from 0
  190. reset_work_coordinates()
  191. # Home if position was mismatched (machine may have been power cycled)
  192. if needs_homing:
  193. logger.info("Homing required due to position mismatch...")
  194. success = home()
  195. if not success:
  196. logger.error("Homing failed during device initialization")
  197. time.sleep(2) # Allow time for the connection to establish
  198. return True
  199. def connect_device(homing=True):
  200. # Initialize LED interface based on configured provider
  201. # Note: DW LEDs are initialized at startup in main.py, so we preserve the existing controller
  202. if state.led_provider == "wled" and state.wled_ip:
  203. state.led_controller = LEDInterface(provider="wled", ip_address=state.wled_ip)
  204. elif state.led_provider == "dw_leds":
  205. # DW LEDs are already initialized in main.py at startup
  206. # Only initialize here if not already set up (e.g., reconnection scenario)
  207. if not state.led_controller or not state.led_controller.is_configured:
  208. state.led_controller = LEDInterface(
  209. provider="dw_leds",
  210. num_leds=state.dw_led_num_leds,
  211. gpio_pin=state.dw_led_gpio_pin,
  212. pixel_order=state.dw_led_pixel_order,
  213. brightness=state.dw_led_brightness / 100.0,
  214. speed=state.dw_led_speed,
  215. intensity=state.dw_led_intensity
  216. )
  217. elif state.led_provider == "hyperion" and state.hyperion_ip:
  218. state.led_controller = LEDInterface(
  219. provider="hyperion",
  220. ip_address=state.hyperion_ip,
  221. port=state.hyperion_port
  222. )
  223. elif state.led_provider == "none" or not state.led_provider:
  224. state.led_controller = None
  225. # For other cases (e.g., wled without IP), preserve existing controller
  226. # Show loading effect
  227. if state.led_controller:
  228. state.led_controller.effect_loading()
  229. ports = list_serial_ports()
  230. # Check auto-connect mode: "__auto__" or None = auto, "__none__" = disabled, else specific port
  231. if state.preferred_port == "__none__":
  232. logger.info("Auto-connect disabled by user preference")
  233. # Skip all auto-connect logic, no connection will be established
  234. # Priority for auto-connect:
  235. # 1. Preferred port (user's explicit choice) if available
  236. # 2. Last used port if available
  237. # 3. First available port as fallback
  238. elif state.preferred_port and state.preferred_port not in ("__auto__", None) and state.preferred_port in ports:
  239. logger.info(f"Connecting to preferred port: {state.preferred_port}")
  240. state.conn = SerialConnection(state.preferred_port)
  241. elif state.port and state.port in ports:
  242. logger.info(f"Connecting to last used port: {state.port}")
  243. state.conn = SerialConnection(state.port)
  244. elif ports:
  245. # Prefer non-deprioritized ports (e.g., USB serial over hardware UART)
  246. preferred_ports = [p for p in ports if p not in DEPRIORITIZED_PORTS]
  247. fallback_ports = [p for p in ports if p in DEPRIORITIZED_PORTS]
  248. if preferred_ports:
  249. logger.info(f"Connecting to first available port: {preferred_ports[0]}")
  250. state.conn = SerialConnection(preferred_ports[0])
  251. elif fallback_ports:
  252. logger.info(f"Connecting to deprioritized port (no better option): {fallback_ports[0]}")
  253. state.conn = SerialConnection(fallback_ports[0])
  254. else:
  255. logger.error("Auto connect failed: No serial ports available")
  256. # state.conn = WebSocketConnection('ws://fluidnc.local:81')
  257. if (state.conn.is_connected() if state.conn else False):
  258. # Check for alarm state and unlock if needed before initializing
  259. if not check_and_unlock_alarm():
  260. logger.error("Failed to unlock device from alarm state")
  261. # Still proceed with device_init but log the issue
  262. device_init(homing)
  263. # Show connected effect, then transition to configured idle effect
  264. if state.led_controller:
  265. logger.info("Showing LED connected effect (green flash)")
  266. state.led_controller.effect_connected()
  267. # Set the configured idle effect after connection
  268. logger.info(f"Setting LED to idle effect: {state.dw_led_idle_effect}")
  269. state.led_controller.effect_idle(state.dw_led_idle_effect)
  270. _start_idle_led_timeout()
  271. def check_and_unlock_alarm():
  272. """
  273. Check if GRBL is in alarm state and unlock it with $X if needed.
  274. Returns True if device is ready (unlocked or no alarm), False on error.
  275. Note: If sensors are physically triggered (Pn:XY), the alarm may persist
  276. but we still return True to allow homing to proceed.
  277. """
  278. try:
  279. logger.info("Checking device status for alarm state...")
  280. # Clear any pending data in buffer first
  281. while state.conn.in_waiting() > 0:
  282. state.conn.readline()
  283. # Send status query
  284. state.conn.send('?\n')
  285. time.sleep(0.2)
  286. # Read response with timeout
  287. max_attempts = 10
  288. response = None
  289. for attempt in range(max_attempts):
  290. if state.conn.in_waiting() > 0:
  291. response = state.conn.readline()
  292. logger.debug(f"Status response: {response}")
  293. if response and ('<' in response or 'Alarm' in response or 'Idle' in response):
  294. break # Got a valid status response
  295. time.sleep(0.1)
  296. if not response:
  297. logger.warning("No status response received, proceeding anyway")
  298. return True
  299. # Check for alarm state
  300. if "Alarm" in response:
  301. logger.warning(f"Device in ALARM state: {response}")
  302. # Send unlock command
  303. logger.info("Sending $X to unlock...")
  304. state.conn.send('$X\n')
  305. time.sleep(1.0) # Give more time for unlock to process
  306. # Clear buffer before verification
  307. while state.conn.in_waiting() > 0:
  308. discarded = state.conn.readline()
  309. logger.debug(f"Discarded response: {discarded}")
  310. # Verify unlock succeeded
  311. state.conn.send('?\n')
  312. time.sleep(0.3)
  313. verify_response = None
  314. for attempt in range(max_attempts):
  315. if state.conn.in_waiting() > 0:
  316. verify_response = state.conn.readline()
  317. logger.debug(f"Verification response: {verify_response}")
  318. if verify_response and '<' in verify_response:
  319. break
  320. time.sleep(0.1)
  321. if verify_response and "Alarm" in verify_response:
  322. # Check if pins are physically triggered (Pn: in response)
  323. if "Pn:" in verify_response:
  324. logger.warning(f"Alarm persists due to triggered sensors: {verify_response}")
  325. logger.warning("Proceeding anyway - homing may clear the sensor state")
  326. return True # Let homing attempt to proceed
  327. else:
  328. logger.error("Failed to unlock device from alarm state")
  329. return False
  330. else:
  331. logger.info("Device successfully unlocked")
  332. return True
  333. else:
  334. logger.info("Device not in alarm state, proceeding normally")
  335. return True
  336. except Exception as e:
  337. logger.error(f"Error checking/unlocking alarm: {e}")
  338. return False
  339. def get_status_response() -> str:
  340. """
  341. Send a status query ('?') and return the response if available.
  342. Accepts both MPos (machine position) and WPos (work position) formats
  343. depending on GRBL's $10 setting.
  344. """
  345. if state.conn is None or not state.conn.is_connected():
  346. logger.warning("Cannot get status response: no active connection")
  347. return False
  348. while True:
  349. try:
  350. state.conn.send('?')
  351. response = state.conn.readline()
  352. # Accept either MPos or WPos format (depends on GRBL $10 setting)
  353. if "MPos" in response or "WPos" in response:
  354. logger.debug(f"Status response: {response}")
  355. return response
  356. except Exception as e:
  357. logger.error(f"Error getting status response: {e}")
  358. return False
  359. time.sleep(1)
  360. def parse_machine_position(response: str):
  361. """
  362. Parse the position from a status response.
  363. Supports both MPos (machine position) and WPos (work position) formats
  364. depending on GRBL's $10 setting.
  365. Expected formats:
  366. "<...|MPos:-994.869,-321.861,0.000|...>"
  367. "<...|WPos:0.000,19.000,0.000|...>"
  368. Returns a tuple (x, y) if found, else None.
  369. """
  370. if "MPos:" not in response and "WPos:" not in response:
  371. return None
  372. try:
  373. # Try MPos first, then WPos
  374. pos_section = next((part for part in response.split("|") if part.startswith("MPos:")), None)
  375. if pos_section is None:
  376. pos_section = next((part for part in response.split("|") if part.startswith("WPos:")), None)
  377. if pos_section:
  378. pos_str = pos_section.split(":", 1)[1]
  379. pos_values = pos_str.split(",")
  380. pos_x = float(pos_values[0])
  381. pos_y = float(pos_values[1])
  382. return pos_x, pos_y
  383. except Exception as e:
  384. logger.error(f"Error parsing position: {e}")
  385. return None
  386. async def send_grbl_coordinates(x, y, speed=600, timeout=30, home=False):
  387. """
  388. Send a G-code command to FluidNC and wait for an 'ok' response.
  389. If no response after set timeout, returns False.
  390. Args:
  391. x: X coordinate
  392. y: Y coordinate
  393. speed: Feed rate in mm/min
  394. timeout: Maximum time in seconds to wait for 'ok' response
  395. home: If True, sends jog command ($J=) instead of G1
  396. Returns:
  397. True on success, False on timeout or error
  398. """
  399. logger.debug(f"Sending G-code: X{x} Y{y} at F{speed}")
  400. overall_start_time = time.time()
  401. max_retries = 3
  402. retry_count = 0
  403. while retry_count < max_retries:
  404. # Check overall timeout
  405. if time.time() - overall_start_time > timeout:
  406. logger.error(f"Timeout waiting for 'ok' response after {timeout}s")
  407. return False
  408. try:
  409. gcode = f"$J=G91 G21 Y{y:.2f} F{speed}" if home else f"G1 X{x:.2f} Y{y:.2f} F{speed}"
  410. await asyncio.to_thread(state.conn.send, gcode + "\n")
  411. logger.debug(f"Sent command: {gcode}")
  412. # Wait for 'ok' response with timeout
  413. response_start = time.time()
  414. response_timeout = min(10, timeout - (time.time() - overall_start_time))
  415. while time.time() - response_start < response_timeout:
  416. # Check overall timeout
  417. if time.time() - overall_start_time > timeout:
  418. logger.error(f"Overall timeout waiting for 'ok' response")
  419. return False
  420. response = await asyncio.to_thread(state.conn.readline)
  421. if response:
  422. logger.debug(f"Response: {response}")
  423. if response.lower().strip() == "ok":
  424. logger.debug("Command execution confirmed.")
  425. return True
  426. elif 'error' in response.lower():
  427. logger.warning(f"Got error response: {response}")
  428. # Don't immediately fail - some errors are recoverable
  429. else:
  430. await asyncio.sleep(0.05)
  431. # Response timeout for this attempt
  432. logger.warning(f"No 'ok' received for {gcode}, retrying... ({retry_count + 1}/{max_retries})")
  433. retry_count += 1
  434. await asyncio.sleep(0.2)
  435. except Exception as e:
  436. error_str = str(e)
  437. logger.warning(f"Error sending command: {error_str}")
  438. # Immediately return for device not configured errors
  439. if "Device not configured" in error_str or "Errno 6" in error_str:
  440. logger.error(f"Device configuration error detected: {error_str}")
  441. state.stop_requested = True
  442. state.conn = None
  443. state.is_connected = False
  444. logger.info("Connection marked as disconnected due to device error")
  445. return False
  446. retry_count += 1
  447. await asyncio.sleep(0.2)
  448. logger.error(f"Failed to receive 'ok' response after {max_retries} retries")
  449. return False
  450. def _detect_firmware():
  451. """
  452. Detect firmware type (FluidNC or GRBL) by sending $I command.
  453. Returns tuple: (firmware_type: str, version: str or None)
  454. firmware_type is 'fluidnc', 'grbl', or 'unknown'
  455. """
  456. if not state.conn or not state.conn.is_connected():
  457. return ('unknown', None)
  458. # Clear buffer first
  459. try:
  460. while state.conn.in_waiting() > 0:
  461. state.conn.readline()
  462. except Exception:
  463. pass
  464. try:
  465. state.conn.send("$I\n")
  466. time.sleep(0.3)
  467. firmware_type = 'unknown'
  468. version = None
  469. start_time = time.time()
  470. while time.time() - start_time < 2.0:
  471. if state.conn.in_waiting() > 0:
  472. response = state.conn.readline()
  473. if response:
  474. logger.debug(f"Firmware detection response: {response}")
  475. response_lower = response.lower()
  476. if 'fluidnc' in response_lower:
  477. firmware_type = 'fluidnc'
  478. # Try to extract version from response like "FluidNC v3.7.2"
  479. if 'v' in response_lower:
  480. parts = response.split()
  481. for part in parts:
  482. if part.lower().startswith('v') and any(c.isdigit() for c in part):
  483. version = part
  484. break
  485. break
  486. elif 'grbl' in response_lower and 'fluidnc' not in response_lower:
  487. firmware_type = 'grbl'
  488. # Try to extract version like "Grbl 1.1h"
  489. parts = response.split()
  490. for i, part in enumerate(parts):
  491. if 'grbl' in part.lower() and i + 1 < len(parts):
  492. version = parts[i + 1]
  493. break
  494. break
  495. elif response.lower().strip() == 'ok':
  496. break
  497. else:
  498. time.sleep(0.05)
  499. # Clear any remaining responses
  500. while state.conn.in_waiting() > 0:
  501. state.conn.readline()
  502. return (firmware_type, version)
  503. except Exception as e:
  504. logger.warning(f"Firmware detection failed: {e}")
  505. return ('unknown', None)
  506. def _get_steps_fluidnc():
  507. """
  508. Get steps/mm from FluidNC using individual setting queries.
  509. Returns tuple: (x_steps_per_mm, y_steps_per_mm) or (None, None) on failure.
  510. Note: Works even when device is in ALARM state (e.g., limit switch active).
  511. """
  512. x_steps = None
  513. y_steps = None
  514. # Clear buffer
  515. try:
  516. while state.conn.in_waiting() > 0:
  517. state.conn.readline()
  518. except Exception:
  519. pass
  520. # Query X steps/mm
  521. try:
  522. state.conn.send("$/axes/x/steps_per_mm\n")
  523. time.sleep(0.2)
  524. start_time = time.time()
  525. while time.time() - start_time < 2.0:
  526. if state.conn.in_waiting() > 0:
  527. response = state.conn.readline()
  528. if response:
  529. logger.debug(f"FluidNC X steps response: {response}")
  530. # Response format: "/axes/x/steps_per_mm=200.000" or similar
  531. if 'steps_per_mm=' in response:
  532. try:
  533. x_steps = float(response.split('=')[1].strip())
  534. state.x_steps_per_mm = x_steps
  535. logger.info(f"X steps per mm (FluidNC): {x_steps}")
  536. except (ValueError, IndexError) as e:
  537. logger.warning(f"Failed to parse X steps: {e}")
  538. break
  539. elif response.lower().strip() == 'ok':
  540. break
  541. elif 'error' in response.lower() or 'alarm' in response.lower():
  542. # Device may be in alarm state (e.g., limit switch active)
  543. # Log and continue - settings queries often work anyway
  544. logger.debug(f"Got error/alarm response, continuing: {response}")
  545. else:
  546. time.sleep(0.05)
  547. except Exception as e:
  548. logger.error(f"Error querying FluidNC X steps: {e}")
  549. # Clear buffer before next query
  550. try:
  551. while state.conn.in_waiting() > 0:
  552. state.conn.readline()
  553. except Exception:
  554. pass
  555. # Query Y steps/mm
  556. try:
  557. state.conn.send("$/axes/y/steps_per_mm\n")
  558. time.sleep(0.2)
  559. start_time = time.time()
  560. while time.time() - start_time < 2.0:
  561. if state.conn.in_waiting() > 0:
  562. response = state.conn.readline()
  563. if response:
  564. logger.debug(f"FluidNC Y steps response: {response}")
  565. if 'steps_per_mm=' in response:
  566. try:
  567. y_steps = float(response.split('=')[1].strip())
  568. state.y_steps_per_mm = y_steps
  569. logger.info(f"Y steps per mm (FluidNC): {y_steps}")
  570. except (ValueError, IndexError) as e:
  571. logger.warning(f"Failed to parse Y steps: {e}")
  572. break
  573. elif response.lower().strip() == 'ok':
  574. break
  575. elif 'error' in response.lower() or 'alarm' in response.lower():
  576. logger.debug(f"Got error/alarm response, continuing: {response}")
  577. else:
  578. time.sleep(0.05)
  579. except Exception as e:
  580. logger.error(f"Error querying FluidNC Y steps: {e}")
  581. # Clear buffer before homing query
  582. try:
  583. while state.conn.in_waiting() > 0:
  584. state.conn.readline()
  585. except Exception:
  586. pass
  587. # Query homing cycle setting (informational - user preference takes precedence)
  588. try:
  589. state.conn.send("$/axes/y/homing/cycle\n")
  590. time.sleep(0.2)
  591. start_time = time.time()
  592. while time.time() - start_time < 1.5:
  593. if state.conn.in_waiting() > 0:
  594. response = state.conn.readline()
  595. if response:
  596. logger.debug(f"FluidNC homing response: {response}")
  597. if 'homing/cycle=' in response:
  598. try:
  599. homing_cycle = int(float(response.split('=')[1].strip()))
  600. # cycle >= 1 means homing is enabled in firmware
  601. firmware_homing = 1 if homing_cycle >= 1 else 0
  602. logger.info(f"Firmware homing setting (cycle): {homing_cycle}, using user preference: {state.homing}")
  603. except (ValueError, IndexError):
  604. pass
  605. break
  606. elif response.lower().strip() == 'ok':
  607. break
  608. else:
  609. time.sleep(0.05)
  610. except Exception as e:
  611. logger.debug(f"Could not query FluidNC homing setting: {e}")
  612. # Clear buffer
  613. try:
  614. while state.conn.in_waiting() > 0:
  615. state.conn.readline()
  616. except Exception:
  617. pass
  618. return (x_steps, y_steps)
  619. def _get_steps_grbl():
  620. """
  621. Get steps/mm from GRBL using $$ command.
  622. Returns tuple: (x_steps_per_mm, y_steps_per_mm) or (None, None) on failure.
  623. Note: Works even when device is in ALARM state (e.g., limit switch active).
  624. $$ command typically responds with settings even during alarm.
  625. """
  626. x_steps_per_mm = None
  627. y_steps_per_mm = None
  628. max_retries = 3
  629. attempt_timeout = 4
  630. for attempt in range(max_retries):
  631. logger.info(f"Requesting GRBL settings with $$ command (attempt {attempt + 1}/{max_retries})")
  632. try:
  633. state.conn.send("$$\n")
  634. except Exception as e:
  635. logger.error(f"Error sending $$ command: {e}")
  636. continue
  637. attempt_start = time.time()
  638. got_ok = False
  639. while time.time() - attempt_start < attempt_timeout:
  640. try:
  641. response = state.conn.readline()
  642. if not response:
  643. continue
  644. logger.debug(f"Raw response: {response}")
  645. for line in response.splitlines():
  646. line = line.strip()
  647. if not line:
  648. continue
  649. logger.debug(f"Config response: {line}")
  650. if line.startswith("$100="):
  651. x_steps_per_mm = float(line.split("=")[1])
  652. state.x_steps_per_mm = x_steps_per_mm
  653. logger.info(f"X steps per mm: {x_steps_per_mm}")
  654. elif line.startswith("$101="):
  655. y_steps_per_mm = float(line.split("=")[1])
  656. state.y_steps_per_mm = y_steps_per_mm
  657. logger.info(f"Y steps per mm: {y_steps_per_mm}")
  658. elif line.startswith("$22="):
  659. firmware_homing = int(line.split('=')[1])
  660. logger.info(f"Firmware homing setting ($22): {firmware_homing}, using user preference: {state.homing}")
  661. elif line.lower() == 'ok':
  662. got_ok = True
  663. logger.debug("Received 'ok' confirmation from GRBL")
  664. elif line.lower().startswith('error') or 'alarm' in line.lower():
  665. # Device may be in alarm state (e.g., limit switch active)
  666. # Log and continue - $$ typically works anyway
  667. logger.debug(f"Got error/alarm during settings query (proceeding): {line}")
  668. if got_ok:
  669. if x_steps_per_mm is not None and y_steps_per_mm is not None:
  670. logger.info("Successfully received all GRBL settings")
  671. break
  672. else:
  673. logger.warning("Received 'ok' but missing some settings")
  674. break
  675. except Exception as e:
  676. logger.error(f"Error reading GRBL response: {e}")
  677. break
  678. if x_steps_per_mm is not None and y_steps_per_mm is not None:
  679. break
  680. if attempt < max_retries - 1:
  681. logger.warning(f"Attempt {attempt + 1} did not get all settings, retrying...")
  682. time.sleep(0.5)
  683. try:
  684. while state.conn.in_waiting() > 0:
  685. state.conn.readline()
  686. except Exception:
  687. pass
  688. return (x_steps_per_mm, y_steps_per_mm)
  689. def get_machine_steps(timeout=10):
  690. """
  691. Get machine steps/mm from the controller (FluidNC or GRBL).
  692. Returns True if successful, False otherwise.
  693. Detects firmware type first:
  694. - FluidNC: Uses targeted $/axes/x/steps_per_mm queries (more reliable)
  695. - GRBL: Falls back to $$ command with retries
  696. """
  697. if not state.conn or not state.conn.is_connected():
  698. logger.error("Cannot get machine steps: No connection available")
  699. return False
  700. # Clear any pending data in the buffer
  701. try:
  702. while state.conn.in_waiting() > 0:
  703. state.conn.readline()
  704. except Exception as e:
  705. logger.warning(f"Error clearing buffer: {e}")
  706. # Verify controller is responsive before querying
  707. try:
  708. state.conn.send("?\n")
  709. time.sleep(0.2)
  710. ready_check_attempts = 5
  711. controller_ready = False
  712. in_alarm = False
  713. for _ in range(ready_check_attempts):
  714. if state.conn.in_waiting() > 0:
  715. response = state.conn.readline()
  716. if response and ('<' in response or 'Idle' in response or 'Alarm' in response):
  717. controller_ready = True
  718. if 'Alarm' in response:
  719. in_alarm = True
  720. logger.info(f"Controller in ALARM state (likely limit switch active), proceeding with settings query: {response.strip()}")
  721. else:
  722. logger.debug(f"Controller ready, status: {response}")
  723. break
  724. time.sleep(0.1)
  725. if not controller_ready:
  726. logger.warning("Controller not responding to status query, proceeding anyway...")
  727. # Clear buffer after readiness check
  728. while state.conn.in_waiting() > 0:
  729. state.conn.readline()
  730. time.sleep(0.1)
  731. except Exception as e:
  732. logger.warning(f"Readiness check failed: {e}, proceeding anyway...")
  733. # Detect firmware type
  734. firmware_type, firmware_version = _detect_firmware()
  735. if firmware_type == 'fluidnc':
  736. if firmware_version:
  737. logger.info(f"Detected FluidNC firmware, version: {firmware_version}")
  738. else:
  739. logger.info("Detected FluidNC firmware (version unknown)")
  740. x_steps_per_mm, y_steps_per_mm = _get_steps_fluidnc()
  741. # Fallback to GRBL method if FluidNC queries failed
  742. if x_steps_per_mm is None or y_steps_per_mm is None:
  743. logger.warning("FluidNC setting queries failed, falling back to $$ command...")
  744. x_steps_per_mm, y_steps_per_mm = _get_steps_grbl()
  745. else:
  746. if firmware_type == 'grbl':
  747. if firmware_version:
  748. logger.info(f"Detected GRBL firmware, version: {firmware_version}")
  749. else:
  750. logger.info("Detected GRBL firmware (version unknown)")
  751. else:
  752. logger.info("Could not detect firmware type, using GRBL commands")
  753. x_steps_per_mm, y_steps_per_mm = _get_steps_grbl()
  754. # Process results and determine table type
  755. settings_complete = (x_steps_per_mm is not None and y_steps_per_mm is not None)
  756. if settings_complete:
  757. if y_steps_per_mm == 180 and x_steps_per_mm == 256:
  758. state.table_type = 'dune_weaver_mini'
  759. elif y_steps_per_mm == 210 and x_steps_per_mm == 256:
  760. state.table_type = 'dune_weaver_mini_pro_byj'
  761. elif y_steps_per_mm == 270 and x_steps_per_mm == 200:
  762. state.table_type = 'dune_weaver_gold'
  763. elif y_steps_per_mm == 287:
  764. state.table_type = 'dune_weaver'
  765. elif y_steps_per_mm == 164:
  766. state.table_type = 'dune_weaver_mini_pro'
  767. elif y_steps_per_mm >= 320:
  768. state.table_type = 'dune_weaver_pro'
  769. else:
  770. state.table_type = None
  771. logger.warning(f"Unknown table type with Y steps/mm: {y_steps_per_mm}")
  772. # Use override if set, otherwise use detected table type
  773. effective_table_type = state.table_type_override or state.table_type
  774. # Set gear ratio based on effective table type (hardcoded)
  775. if effective_table_type in ['dune_weaver_mini', 'dune_weaver_mini_pro', 'dune_weaver_mini_pro_byj', 'dune_weaver_gold']:
  776. state.gear_ratio = 6.25
  777. else:
  778. state.gear_ratio = 10
  779. # Check for environment variable override
  780. gear_ratio_override = os.getenv('GEAR_RATIO')
  781. if gear_ratio_override is not None:
  782. try:
  783. state.gear_ratio = float(gear_ratio_override)
  784. logger.info(f"Machine type detected: {state.table_type}, effective: {effective_table_type}, gear ratio: {state.gear_ratio} (from GEAR_RATIO env var)")
  785. except ValueError:
  786. logger.error(f"Invalid GEAR_RATIO env var value: {gear_ratio_override}, using default: {state.gear_ratio}")
  787. logger.info(f"Machine type detected: {state.table_type}, effective: {effective_table_type}, gear ratio: {state.gear_ratio} (hardcoded)")
  788. elif state.table_type_override:
  789. logger.info(f"Machine type detected: {state.table_type}, overridden to: {effective_table_type}, gear ratio: {state.gear_ratio}")
  790. else:
  791. logger.info(f"Machine type detected: {state.table_type}, gear ratio: {state.gear_ratio} (hardcoded)")
  792. return True
  793. else:
  794. missing = []
  795. if x_steps_per_mm is None: missing.append("X steps/mm")
  796. if y_steps_per_mm is None: missing.append("Y steps/mm")
  797. logger.error(f"Failed to get all machine parameters after {timeout}s. Missing: {', '.join(missing)}")
  798. return False
  799. def home(timeout=120):
  800. """
  801. Perform homing sequence based on configured mode:
  802. Mode 0 (Crash):
  803. - Y axis moves -22mm (or -30mm for mini) until physical stop
  804. - Set theta=0, rho=0 (no x0 y0 command)
  805. Mode 1 (Sensor):
  806. - Send $H command to home both X and Y axes
  807. - Wait for [MSG:Homed:X] and [MSG:Homed:Y] messages
  808. - Send x0 y0 to zero positions
  809. - Set theta to compass offset, rho=0
  810. Args:
  811. timeout: Maximum time in seconds to wait for homing to complete (default: 120)
  812. Increased from 90s to allow buffer after soft reset recovery
  813. """
  814. import threading
  815. import math
  816. # Check for alarm state before homing and unlock if needed
  817. if not check_and_unlock_alarm():
  818. logger.error("Failed to unlock device from alarm state, cannot proceed with homing")
  819. return False
  820. # Flag to track if homing completed
  821. homing_complete = threading.Event()
  822. homing_success = False
  823. def home_internal():
  824. nonlocal homing_success
  825. effective_table_type = state.table_type_override or state.table_type
  826. homing_speed = 400
  827. if effective_table_type == 'dune_weaver_mini':
  828. homing_speed = 100
  829. try:
  830. if state.homing == 1:
  831. # Mode 1: Sensor-based homing using $H
  832. logger.info("Using sensor-based homing mode ($H)")
  833. # Clear any pending responses
  834. state.homed_x = False
  835. state.homed_y = False
  836. # Clear any stale data from previous operations
  837. try:
  838. while state.conn.in_waiting() > 0:
  839. stale = state.conn.readline()
  840. logger.debug(f"Cleared stale data before homing: {stale}")
  841. except Exception:
  842. pass
  843. # Send $H command
  844. state.conn.send("$H\n")
  845. logger.info("Sent $H command, waiting for homing messages...")
  846. # Wait for [MSG:Homed:X] and [MSG:Homed:Y] messages
  847. max_wait_time = 60 # 60 seconds - boot recovery needs more time
  848. start_time = time.time()
  849. while (time.time() - start_time) < max_wait_time:
  850. try:
  851. response = state.conn.readline()
  852. if response:
  853. logger.debug(f"Homing response: {response}")
  854. # Check for homing messages
  855. if "[MSG:Homed:X]" in response:
  856. state.homed_x = True
  857. logger.info("Received [MSG:Homed:X]")
  858. if "[MSG:Homed:Y]" in response:
  859. state.homed_y = True
  860. logger.info("Received [MSG:Homed:Y]")
  861. # Break if we've received both messages
  862. if state.homed_x and state.homed_y:
  863. logger.info("Received both homing confirmation messages")
  864. break
  865. except Exception as e:
  866. logger.error(f"Error reading homing response: {e}")
  867. time.sleep(0.1)
  868. if not (state.homed_x and state.homed_y):
  869. logger.warning(f"Did not receive all homing messages (X:{state.homed_x}, Y:{state.homed_y}), unlocking and continuing...")
  870. # Unlock machine to clear any alarm state
  871. state.conn.send("$X\n")
  872. time.sleep(0.5)
  873. # Wait for idle state after $H
  874. logger.info("Waiting for device to reach idle state after $H...")
  875. idle_reached = check_idle()
  876. if not idle_reached:
  877. logger.error("Device did not reach idle state after $H command")
  878. homing_complete.set()
  879. return
  880. # If X homed but Y failed, fallback to crash homing for Y
  881. if state.homed_x and not state.homed_y:
  882. logger.warning("Sensor homing incomplete (Y failed) - falling back to crash homing")
  883. # Perform crash homing as fallback
  884. logger.info(f"Executing crash homing fallback at {homing_speed} mm/min")
  885. loop = asyncio.new_event_loop()
  886. asyncio.set_event_loop(loop)
  887. try:
  888. if effective_table_type == 'dune_weaver_mini':
  889. result = loop.run_until_complete(send_grbl_coordinates(0, -30, homing_speed, home=True))
  890. if result == False:
  891. logger.error("Crash homing fallback failed")
  892. homing_complete.set()
  893. return
  894. else:
  895. result = loop.run_until_complete(send_grbl_coordinates(0, -22, homing_speed, home=True))
  896. if result == False:
  897. logger.error("Crash homing fallback failed")
  898. homing_complete.set()
  899. return
  900. finally:
  901. loop.close()
  902. # Wait for idle after crash homing
  903. logger.info("Waiting for device to reach idle state after crash homing fallback...")
  904. idle_reached = check_idle()
  905. if not idle_reached:
  906. logger.error("Device did not reach idle state after crash homing fallback")
  907. homing_complete.set()
  908. return
  909. # Set position like crash homing does
  910. state.current_theta = 0
  911. state.current_rho = 0
  912. logger.info("Crash homing fallback completed - theta=0, rho=0")
  913. elif not state.homed_x and not state.homed_y:
  914. # Neither axis homed - this is a failure, don't proceed
  915. logger.error("Sensor homing failed - neither axis homed")
  916. homing_complete.set()
  917. return
  918. else:
  919. # Send x0 y0 to zero both positions using send_grbl_coordinates
  920. logger.info(f"Zeroing positions with x0 y0 f{homing_speed}")
  921. # Run async function in new event loop
  922. loop = asyncio.new_event_loop()
  923. asyncio.set_event_loop(loop)
  924. try:
  925. # Send G1 X0 Y0 F{homing_speed}
  926. result = loop.run_until_complete(send_grbl_coordinates(0, 0, homing_speed))
  927. if result == False:
  928. logger.error("Position zeroing failed - send_grbl_coordinates returned False")
  929. homing_complete.set()
  930. return
  931. logger.info("Position zeroing completed successfully")
  932. finally:
  933. loop.close()
  934. # Wait for device to reach idle state after zeroing movement
  935. logger.info("Waiting for device to reach idle state after zeroing...")
  936. idle_reached = check_idle()
  937. if not idle_reached:
  938. logger.error("Device did not reach idle state after zeroing")
  939. homing_complete.set()
  940. return
  941. # Set current position based on compass reference point (sensor mode only)
  942. offset_radians = math.radians(state.angular_homing_offset_degrees)
  943. state.current_theta = offset_radians
  944. state.current_rho = 0
  945. logger.info(f"Sensor homing completed - theta set to {state.angular_homing_offset_degrees}° ({offset_radians:.3f} rad), rho=0")
  946. else:
  947. logger.info(f"Using crash homing mode at {homing_speed} mm/min")
  948. # Run async function in new event loop
  949. loop = asyncio.new_event_loop()
  950. asyncio.set_event_loop(loop)
  951. try:
  952. if effective_table_type == 'dune_weaver_mini':
  953. result = loop.run_until_complete(send_grbl_coordinates(0, -30, homing_speed, home=True))
  954. if result == False:
  955. logger.error("Crash homing failed - send_grbl_coordinates returned False")
  956. homing_complete.set()
  957. return
  958. state.machine_y -= 30
  959. else:
  960. result = loop.run_until_complete(send_grbl_coordinates(0, -22, homing_speed, home=True))
  961. if result == False:
  962. logger.error("Crash homing failed - send_grbl_coordinates returned False")
  963. homing_complete.set()
  964. return
  965. state.machine_y -= 22
  966. finally:
  967. loop.close()
  968. # Wait for device to reach idle state after crash homing
  969. logger.info("Waiting for device to reach idle state after crash homing...")
  970. idle_reached = check_idle()
  971. if not idle_reached:
  972. logger.error("Device did not reach idle state after crash homing")
  973. homing_complete.set()
  974. return
  975. # Crash homing just sets theta and rho to 0 (no x0 y0 command)
  976. state.current_theta = 0
  977. state.current_rho = 0
  978. logger.info("Crash homing completed - theta=0, rho=0")
  979. # Update machine position from hardware after homing
  980. logger.info("Updating machine position after homing...")
  981. try:
  982. pos = get_machine_position()
  983. if pos and pos[0] is not None and pos[1] is not None:
  984. state.machine_x, state.machine_y = pos
  985. state.save()
  986. logger.info(f"Machine position updated after homing: X={state.machine_x}, Y={state.machine_y}")
  987. else:
  988. logger.warning("Could not get machine position after homing")
  989. except Exception as e:
  990. logger.error(f"Error updating machine position after homing: {e}")
  991. homing_success = True
  992. homing_complete.set()
  993. except Exception as e:
  994. logger.error(f"Error during homing: {e}")
  995. homing_complete.set()
  996. # Start homing in a separate thread
  997. homing_thread = threading.Thread(target=home_internal)
  998. homing_thread.daemon = True
  999. homing_thread.start()
  1000. # Wait for homing to complete or timeout
  1001. if not homing_complete.wait(timeout):
  1002. logger.error(f"Homing timeout after {timeout} seconds")
  1003. # Try to stop any ongoing movement
  1004. try:
  1005. if state.conn and state.conn.is_connected():
  1006. state.conn.send("!\n") # Send feed hold
  1007. time.sleep(0.1)
  1008. state.conn.send("\x18\n") # Send reset
  1009. except Exception as e:
  1010. logger.error(f"Error stopping movement after timeout: {e}")
  1011. return False
  1012. if not homing_success:
  1013. logger.error("Homing failed")
  1014. return False
  1015. logger.info("Homing completed successfully")
  1016. return True
  1017. def check_idle():
  1018. """
  1019. Continuously check if the device is idle (synchronous version).
  1020. """
  1021. logger.info("Checking idle")
  1022. while True:
  1023. response = get_status_response()
  1024. if response and "Idle" in response:
  1025. logger.info("Device is idle")
  1026. # Schedule async update_machine_position in the existing event loop
  1027. try:
  1028. # Try to schedule in existing event loop if available
  1029. try:
  1030. loop = asyncio.get_running_loop()
  1031. # Create a task but don't await it (fire and forget)
  1032. asyncio.create_task(update_machine_position())
  1033. logger.debug("Scheduled machine position update task")
  1034. except RuntimeError:
  1035. # No event loop running, skip machine position update
  1036. logger.debug("No event loop running, skipping machine position update")
  1037. except Exception as e:
  1038. logger.error(f"Error scheduling machine position update: {e}")
  1039. return True
  1040. time.sleep(1)
  1041. async def check_idle_async(timeout: float = 30.0):
  1042. """
  1043. Continuously check if the device is idle (async version).
  1044. Args:
  1045. timeout: Maximum seconds to wait for idle state (default 30s)
  1046. Returns:
  1047. True if device became idle, False if timeout or stop requested
  1048. """
  1049. logger.info("Checking idle (async)")
  1050. start_time = asyncio.get_event_loop().time()
  1051. while True:
  1052. # Check if stop was requested - exit early
  1053. if state.stop_requested:
  1054. logger.info("Stop requested during idle check, exiting early")
  1055. return False
  1056. # Check timeout
  1057. elapsed = asyncio.get_event_loop().time() - start_time
  1058. if elapsed > timeout:
  1059. logger.warning(f"Timeout ({timeout}s) waiting for device idle state")
  1060. return False
  1061. response = await asyncio.to_thread(get_status_response)
  1062. if response and "Idle" in response:
  1063. logger.info("Device is idle")
  1064. try:
  1065. await update_machine_position()
  1066. except Exception as e:
  1067. logger.error(f"Error updating machine position: {e}")
  1068. return True
  1069. await asyncio.sleep(1)
  1070. def is_machine_idle() -> bool:
  1071. """
  1072. Single check to see if the machine is currently idle.
  1073. Does not loop - returns immediately with current status.
  1074. Returns:
  1075. True if machine is idle, False otherwise
  1076. """
  1077. if not state.conn or not state.conn.is_connected():
  1078. logger.debug("No connection - machine not idle")
  1079. return False
  1080. try:
  1081. state.conn.send('?')
  1082. response = state.conn.readline()
  1083. if response and "Idle" in response:
  1084. logger.debug("Machine status: Idle")
  1085. return True
  1086. else:
  1087. logger.debug(f"Machine status: {response}")
  1088. return False
  1089. except Exception as e:
  1090. logger.error(f"Error checking machine idle status: {e}")
  1091. return False
  1092. def get_machine_position(timeout=5):
  1093. """
  1094. Query the device for its position.
  1095. Supports both MPos and WPos formats (depends on GRBL $10 setting).
  1096. """
  1097. start_time = time.time()
  1098. while time.time() - start_time < timeout:
  1099. try:
  1100. state.conn.send('?')
  1101. response = state.conn.readline()
  1102. logger.debug(f"Raw status response: {response}")
  1103. # Accept either MPos or WPos format
  1104. if "MPos" in response or "WPos" in response:
  1105. pos = parse_machine_position(response)
  1106. if pos:
  1107. machine_x, machine_y = pos
  1108. logger.debug(f"Machine position: X={machine_x}, Y={machine_y}")
  1109. return machine_x, machine_y
  1110. except Exception as e:
  1111. logger.error(f"Error getting machine position: {e}")
  1112. return
  1113. time.sleep(0.1)
  1114. logger.warning("Timeout reached waiting for machine position")
  1115. return None, None
  1116. async def update_machine_position():
  1117. if (state.conn.is_connected() if state.conn else False):
  1118. try:
  1119. logger.info('Saving machine position')
  1120. state.machine_x, state.machine_y = await asyncio.to_thread(get_machine_position)
  1121. await asyncio.to_thread(state.save)
  1122. logger.info(f'Machine position saved: {state.machine_x}, {state.machine_y}')
  1123. except Exception as e:
  1124. logger.error(f"Error updating machine position: {e}")
  1125. def perform_soft_reset_sync(max_retries: int = 5):
  1126. """
  1127. Synchronous version of soft reset for use during device initialization.
  1128. Supports both FluidNC ($Bye) and GRBL (Ctrl+X / 0x18) firmware.
  1129. Triggers a software reset which clears position counters to 0.
  1130. This is more reliable than G92 which only sets a work coordinate offset
  1131. without changing the actual machine position (MPos).
  1132. IMPORTANT: Position is only reset to (0,0) if confirmation is received.
  1133. This prevents position drift from accumulating over long operation periods.
  1134. Uses exponential backoff for retries:
  1135. - Attempt 1: 5s timeout
  1136. - Attempt 2: 7.5s timeout, 1s delay before retry
  1137. - Attempt 3: 11s timeout, 2s delay before retry
  1138. - Attempt 4: 17s timeout, 4s delay before retry
  1139. - Attempt 5: 25s timeout, 8s delay before retry
  1140. Args:
  1141. max_retries: Maximum number of reset attempts (default 5)
  1142. Returns:
  1143. True if reset confirmed, False if all attempts failed
  1144. """
  1145. if not state.conn or not state.conn.is_connected():
  1146. logger.warning("Cannot perform soft reset: no active connection")
  1147. return False
  1148. try:
  1149. # Detect firmware type to use appropriate reset command
  1150. firmware_type, version = _detect_firmware()
  1151. logger.info(f"Detected firmware: {firmware_type} {version or ''}")
  1152. logger.info(f"Performing soft reset (was: X={state.machine_x:.2f}, Y={state.machine_y:.2f})")
  1153. for attempt in range(max_retries):
  1154. # Exponential backoff: 5s * 1.5^attempt → 5s, 7.5s, 11s, 17s, 25s
  1155. timeout = 5.0 * (1.5 ** attempt)
  1156. logger.info(f"Reset attempt {attempt + 1}/{max_retries} (timeout: {timeout:.1f}s)")
  1157. # Clear any pending data first
  1158. if isinstance(state.conn, SerialConnection) and state.conn.ser:
  1159. state.conn.ser.reset_input_buffer()
  1160. # Send appropriate reset command based on firmware
  1161. if firmware_type == 'fluidnc':
  1162. # FluidNC uses $Bye for soft reset
  1163. if isinstance(state.conn, SerialConnection) and state.conn.ser:
  1164. state.conn.ser.write(b'$Bye\n')
  1165. state.conn.ser.flush()
  1166. logger.info(f"$Bye sent directly via serial to {state.port}")
  1167. else:
  1168. state.conn.send('$Bye\n')
  1169. logger.info("$Bye sent via connection abstraction")
  1170. else:
  1171. # GRBL uses Ctrl+X (0x18) for soft reset
  1172. if isinstance(state.conn, SerialConnection) and state.conn.ser:
  1173. state.conn.ser.write(b'\x18')
  1174. state.conn.ser.flush()
  1175. logger.info(f"Ctrl+X (0x18) sent directly via serial to {state.port}")
  1176. else:
  1177. state.conn.send('\x18')
  1178. logger.info("Ctrl+X (0x18) sent via connection abstraction")
  1179. # Wait for controller to fully restart
  1180. # FluidNC sequence: [MSG:INFO: Restarting] -> ... -> "Grbl 3.9 [FluidNC...]"
  1181. # GRBL sequence: "Grbl 1.1h ['$' for help]"
  1182. start_time = time.time()
  1183. reset_confirmed = False
  1184. while time.time() - start_time < timeout:
  1185. try:
  1186. response = state.conn.readline()
  1187. if response:
  1188. logger.debug(f"Reset response: {response}")
  1189. # Wait for the "Grbl" startup banner - this means fully ready
  1190. if response.startswith("Grbl") or "fluidnc" in response.lower():
  1191. reset_confirmed = True
  1192. logger.info(f"Controller restart complete: {response}")
  1193. break
  1194. except Exception:
  1195. pass
  1196. time.sleep(0.05)
  1197. if reset_confirmed:
  1198. # Small delay to let controller fully stabilize
  1199. time.sleep(0.2)
  1200. # Unlock controller in case it's in alarm state after reset
  1201. logger.info("Sending $X to unlock controller after reset")
  1202. state.conn.send("$X\n")
  1203. # Wait for ok response
  1204. unlock_start = time.time()
  1205. while time.time() - unlock_start < 1.0:
  1206. try:
  1207. response = state.conn.readline()
  1208. if response:
  1209. logger.debug(f"$X response: {response}")
  1210. if response.lower() == "ok":
  1211. logger.info("Controller unlocked")
  1212. break
  1213. except Exception:
  1214. pass
  1215. time.sleep(0.05)
  1216. # Only reset state positions when confirmation received
  1217. state.machine_x = 0.0
  1218. state.machine_y = 0.0
  1219. reset_cmd = '$Bye' if firmware_type == 'fluidnc' else 'Ctrl+X'
  1220. logger.info(f"Machine position reset to 0 via {reset_cmd} soft reset")
  1221. # Save the reset position
  1222. state.save()
  1223. logger.info(f"Machine position saved: {state.machine_x}, {state.machine_y}")
  1224. return True
  1225. # Retry after failed attempt with exponential backoff delay
  1226. if attempt < max_retries - 1:
  1227. backoff_delay = 1.0 * (2 ** attempt) # 1s, 2s, 4s, 8s
  1228. logger.warning(f"Reset attempt {attempt + 1}/{max_retries} failed, retrying in {backoff_delay:.0f}s...")
  1229. time.sleep(backoff_delay)
  1230. # All attempts failed - DO NOT reset position to prevent drift
  1231. logger.error(
  1232. f"All {max_retries} reset attempts failed - no confirmation received. "
  1233. f"Position NOT reset (still: X={state.machine_x:.2f}, Y={state.machine_y:.2f}). "
  1234. "This may indicate communication issues or controller not responding."
  1235. )
  1236. return False
  1237. except Exception as e:
  1238. logger.error(f"Error performing soft reset: {e}")
  1239. return False
  1240. async def perform_soft_reset():
  1241. """
  1242. Async version of soft reset for use in async contexts (API endpoints, pattern manager).
  1243. Wraps the sync version in a thread to avoid blocking the event loop.
  1244. """
  1245. return await asyncio.to_thread(perform_soft_reset_sync)
  1246. def reset_work_coordinates():
  1247. """
  1248. Clear all work coordinate offsets for a clean start.
  1249. This ensures the work coordinate system starts fresh on each connection,
  1250. preventing accumulated offsets from previous sessions from affecting
  1251. pattern execution.
  1252. G92.1: Clears any G92 offset (resets work coordinates to machine coordinates)
  1253. G10 L2 P1 X0 Y0: Sets G54 work offset to 0 (for completeness)
  1254. """
  1255. if not state.conn or not state.conn.is_connected():
  1256. logger.warning("Cannot reset work coordinates: no active connection")
  1257. return False
  1258. try:
  1259. logger.info("Resetting work coordinate offsets")
  1260. # Clear any stale input data first
  1261. try:
  1262. while state.conn.in_waiting() > 0:
  1263. state.conn.readline()
  1264. except Exception:
  1265. pass
  1266. # Clear G92 offset
  1267. state.conn.send("G92.1\n")
  1268. time.sleep(0.2)
  1269. # Wait for 'ok' response
  1270. start_time = time.time()
  1271. got_ok = False
  1272. while time.time() - start_time < 2.0:
  1273. if state.conn.in_waiting() > 0:
  1274. response = state.conn.readline()
  1275. if response:
  1276. logger.debug(f"G92.1 response: {response}")
  1277. if response.lower() == "ok":
  1278. got_ok = True
  1279. break
  1280. elif "error" in response.lower():
  1281. logger.warning(f"G92.1 error: {response}")
  1282. break
  1283. time.sleep(0.05)
  1284. if not got_ok:
  1285. logger.warning("Did not receive 'ok' for G92.1, continuing anyway")
  1286. # Set G54 offset to 0 (optional, for completeness)
  1287. state.conn.send("G10 L2 P1 X0 Y0\n")
  1288. time.sleep(0.2)
  1289. # Wait for 'ok' response
  1290. start_time = time.time()
  1291. got_ok = False
  1292. while time.time() - start_time < 2.0:
  1293. if state.conn.in_waiting() > 0:
  1294. response = state.conn.readline()
  1295. if response:
  1296. logger.debug(f"G10 response: {response}")
  1297. if response.lower() == "ok":
  1298. got_ok = True
  1299. break
  1300. elif "error" in response.lower():
  1301. logger.warning(f"G10 error: {response}")
  1302. break
  1303. time.sleep(0.05)
  1304. if not got_ok:
  1305. logger.warning("Did not receive 'ok' for G10 L2 P1 X0 Y0, continuing anyway")
  1306. # Reset machine_x to 0 since work coordinates now start at 0
  1307. state.machine_x = 0.0
  1308. logger.info("Work coordinates reset complete")
  1309. return True
  1310. except Exception as e:
  1311. logger.error(f"Error resetting work coordinates: {e}")
  1312. return False
  1313. def restart_connection(homing=False):
  1314. """
  1315. Restart the connection. If a connection exists, close it and attempt to establish a new one.
  1316. It will try to connect via serial first (if available), otherwise it will fall back to websocket.
  1317. The new connection is saved to state.conn.
  1318. Returns:
  1319. True if the connection was restarted successfully, False otherwise.
  1320. """
  1321. try:
  1322. if (state.conn.is_connected() if state.conn else False):
  1323. logger.info("Closing current connection...")
  1324. state.conn.close()
  1325. except Exception as e:
  1326. logger.error(f"Error while closing connection: {e}")
  1327. # Clear the connection reference.
  1328. state.conn = None
  1329. logger.info("Attempting to restart connection...")
  1330. try:
  1331. connect_device(homing) # This will set state.conn appropriately.
  1332. if (state.conn.is_connected() if state.conn else False):
  1333. logger.info("Connection restarted successfully.")
  1334. return True
  1335. else:
  1336. logger.error("Failed to restart connection.")
  1337. return False
  1338. except Exception as e:
  1339. logger.error(f"Error restarting connection: {e}")
  1340. return False