feat(hardware-testing): flex stacker diagnostic script for axes (#16898)

hardware-testing/hardware_testing/modules/flex_stacker_evt_qc/config.py

@@ -7,13 +7,19 @@
 
 from . import (
     test_connectivity,
+    test_z_axis,
+    test_x_axis,
+    test_l_axis,
 )
 
 
 class TestSection(enum.Enum):
     """Test Section."""
 
     CONNECTIVITY = "CONNECTIVITY"
+    Z_AXIS = "Z_AXIS"
+    L_AXIS = "L_AXIS"
+    X_AXIS = "X_AXIS"
 
 
 @dataclass
@@ -29,6 +35,18 @@ class TestConfig:
         TestSection.CONNECTIVITY,
         test_connectivity.run,
     ),
+    (
+        TestSection.Z_AXIS,
+        test_z_axis.run,
+    ),
+    (
+        TestSection.L_AXIS,
+        test_l_axis.run,
+    ),
+    (
+        TestSection.X_AXIS,
+        test_x_axis.run,
+    ),
 ]
 
 
@@ -40,6 +58,18 @@ def build_report(test_name: str) -> CSVReport:
             CSVSection(
                 title=TestSection.CONNECTIVITY.value,
                 lines=test_connectivity.build_csv_lines(),
-            )
+            ),
+            CSVSection(
+                title=TestSection.Z_AXIS.value,
+                lines=test_z_axis.build_csv_lines(),
+            ),
+            CSVSection(
+                title=TestSection.L_AXIS.value,
+                lines=test_l_axis.build_csv_lines(),
+            ),
+            CSVSection(
+                title=TestSection.X_AXIS.value,
+                lines=test_x_axis.build_csv_lines(),
+            ),
         ],
     )

hardware-testing/hardware_testing/modules/flex_stacker_evt_qc/driver.py

@@ -26,6 +26,53 @@ class StackerInfo:
     sn: str
 
 
+class StackerAxis(Enum):
+    """Stacker Axis."""
+
+    X = "X"
+    Z = "Z"
+    L = "L"
+
+    def __str__(self) -> str:
+        """Name."""
+        return self.name
+
+
+class Direction(Enum):
+    """Direction."""
+
+    RETRACT = 0
+    EXTENT = 1
+
+    def __str__(self) -> str:
+        """Convert to tag for clear logging."""
+        return "negative" if self == Direction.RETRACT else "positive"
+
+    def opposite(self) -> "Direction":
+        """Get opposite direction."""
+        return Direction.EXTENT if self == Direction.RETRACT else Direction.RETRACT
+
+    def distance(self, distance: float) -> float:
+        """Get signed distance, where retract direction is negative."""
+        return distance * -1 if self == Direction.RETRACT else distance
+
+
+@dataclass
+class MoveParams:
+    """Move Parameters."""
+
+    max_speed: float | None = None
+    acceleration: float | None = None
+    max_speed_discont: float | None = None
+
+    def __str__(self) -> str:
+        """Convert to string."""
+        v = "V:" + str(self.max_speed) if self.max_speed else ""
+        a = "A:" + str(self.acceleration) if self.acceleration else ""
+        d = "D:" + str(self.max_speed_discont) if self.max_speed_discont else ""
+        return f"{v} {a} {d}".strip()
+
+
 class FlexStacker:
     """FLEX Stacker Driver."""
 
@@ -87,6 +134,66 @@ def set_serial_number(self, sn: str) -> None:
             return
         self._send_and_recv(f"M996 {sn}\n", "M996 OK")
 
+    def get_limit_switch(self, axis: StackerAxis, direction: Direction) -> bool:
+        """Get limit switch status.
+
+        :return: True if limit switch is triggered, False otherwise
+        """
+        if self._simulating:
+            return True
+
+        _LS_RE = re.compile(rf"^M119 .*{axis.name}{direction.name[0]}:(\d) .* OK\n")
+        res = self._send_and_recv("M119\n", "M119 XE:")
+        match = _LS_RE.match(res)
+        assert match, f"Incorrect Response for limit switch: {res}"
+        return bool(int(match.group(1)))
+
+    def get_platform_sensor(self, direction: Direction) -> bool:
+        """Get platform sensor status.
+
+        :return: True if platform is present, False otherwise
+        """
+        if self._simulating:
+            return True
+
+        _LS_RE = re.compile(rf"^M121 .*{direction.name[0]}:(\d) .* OK\n")
+        res = self._send_and_recv("M121\n", "M119 E:")
+        match = _LS_RE.match(res)
+        assert match, f"Incorrect Response for platform sensor: {res}"
+        return bool(int(match.group(1)))
+
+    def get_hopper_door_closed(self) -> bool:
+        """Get whether or not door is closed.
+
+        :return: True if door is closed, False otherwise
+        """
+        if self._simulating:
+            return True
+
+        _LS_RE = re.compile(r"^M122 (\d) OK\n")
+        res = self._send_and_recv("M122\n", "M122 ")
+        match = _LS_RE.match(res)
+        assert match, f"Incorrect Response for hopper door switch: {res}"
+        return bool(int(match.group(1)))
+
+    def move_in_mm(
+        self, axis: StackerAxis, distance: float, params: MoveParams | None = None
+    ) -> None:
+        """Move axis."""
+        if self._simulating:
+            return
+        self._send_and_recv(f"G0 {axis.name}{distance} {params or ''}\n", "G0 OK")
+
+    def move_to_limit_switch(
+        self, axis: StackerAxis, direction: Direction, params: MoveParams | None = None
+    ) -> None:
+        """Move until limit switch is triggered."""
+        if self._simulating:
+            return
+        self._send_and_recv(
+            f"G5 {axis.name}{direction.value} {params or ''}\n", "G0 OK"
+        )
+
     def __del__(self) -> None:
         """Close serial port."""
         if not self._simulating:

hardware-testing/hardware_testing/modules/flex_stacker_evt_qc/test_l_axis.py

@@ -0,0 +1,70 @@
+"""Test L Axis."""
+from typing import List, Union
+from hardware_testing.data import ui
+from hardware_testing.data.csv_report import (
+    CSVReport,
+    CSVLine,
+    CSVLineRepeating,
+    CSVResult,
+)
+
+from .driver import FlexStacker, StackerAxis, Direction
+
+
+class LimitSwitchError(Exception):
+    """Limit Switch Error."""
+
+    pass
+
+
+def build_csv_lines() -> List[Union[CSVLine, CSVLineRepeating]]:
+    """Build CSV Lines."""
+    return [
+        CSVLine("trigger-latch-switch", [CSVResult]),
+        CSVLine("release/open-latch", [CSVResult]),
+        CSVLine("hold/close-latch", [CSVResult]),
+    ]
+
+
+def get_latch_held_switch(driver: FlexStacker) -> bool:
+    """Get limit switch."""
+    held_switch = driver.get_limit_switch(StackerAxis.L, Direction.RETRACT)
+    print("(Held Switch triggered) : ", held_switch)
+    return held_switch
+
+
+def close_latch(driver: FlexStacker) -> None:
+    """Close latch."""
+    driver.move_to_limit_switch(StackerAxis.L, Direction.EXTENT)
+
+
+def open_latch(driver: FlexStacker) -> None:
+    """Open latch."""
+    driver.move_in_mm(StackerAxis.L, -22)
+
+
+def run(driver: FlexStacker, report: CSVReport, section: str) -> None:
+    """Run."""
+    if not get_latch_held_switch(driver):
+        print("Switch is not triggered, try to trigger it by closing latch...")
+        close_latch(driver)
+        if not get_latch_held_switch(driver):
+            print("!!! Held switch is still not triggered !!!")
+            report(section, "trigger-latch-switch", [CSVResult.FAIL])
+            return
+
+    report(section, "trigger-latch-switch", [CSVResult.PASS])
+
+    ui.print_header("Latch Release/Open")
+    open_latch(driver)
+    success = not get_latch_held_switch(driver)
+    report(section, "release/open-latch", [CSVResult.from_bool(success)])
+
+    ui.print_header("Latch Hold/Close")
+    if not success:
+        print("Latch must be open to close it")
+        report(section, "hold/close-latch", [CSVResult.FAIL])
+    else:
+        close_latch(driver)
+        success = get_latch_held_switch(driver)
+        report(section, "hold/close-latch", [CSVResult.from_bool(success)])

hardware-testing/hardware_testing/modules/flex_stacker_evt_qc/test_x_axis.py

@@ -0,0 +1,81 @@
+"""Test X Axis."""
+from typing import List, Union
+from hardware_testing.data import ui
+from hardware_testing.data.csv_report import (
+    CSVReport,
+    CSVLine,
+    CSVLineRepeating,
+    CSVResult,
+)
+
+from .utils import test_limit_switches_per_direction
+from .driver import FlexStacker, StackerAxis, Direction
+
+
+def build_csv_lines() -> List[Union[CSVLine, CSVLineRepeating]]:
+    """Build CSV Lines."""
+    return [
+        CSVLine(
+            "limit-switch-trigger-positive-untrigger-negative", [bool, bool, CSVResult]
+        ),
+        CSVLine(
+            "limit-switch-trigger-negative-untrigger-positive", [bool, bool, CSVResult]
+        ),
+        CSVLine(
+            "platform-sensor-trigger-positive-untrigger-negative",
+            [bool, bool, CSVResult],
+        ),
+        CSVLine(
+            "platform-sensor-trigger-negative-untrigger-positive",
+            [bool, bool, CSVResult],
+        ),
+    ]
+
+
+def test_platform_sensors_for_direction(
+    driver: FlexStacker, direction: Direction, report: CSVReport, section: str
+) -> None:
+    """Test platform sensors for a given direction."""
+    ui.print_header(f"Platform Sensor - {direction} direction")
+    sensor_result = driver.get_platform_sensor(direction)
+    opposite_result = not driver.get_platform_sensor(direction.opposite())
+    print(f"{direction} sensor triggered: {sensor_result}")
+    print(f"{direction.opposite()} sensor untriggered: {opposite_result}")
+    report(
+        section,
+        f"platform-sensor-trigger-{direction}-untrigger-{direction.opposite()}",
+        [
+            sensor_result,
+            opposite_result,
+            CSVResult.from_bool(sensor_result and opposite_result),
+        ],
+    )
+
+
+def platform_is_removed(driver: FlexStacker) -> bool:
+    """Check if the platform is removed from the carrier."""
+    plus_side = driver.get_platform_sensor(Direction.EXTENT)
+    minus_side = driver.get_platform_sensor(Direction.RETRACT)
+    return not plus_side and not minus_side
+
+
+def run(driver: FlexStacker, report: CSVReport, section: str) -> None:
+    """Run."""
+    if not driver._simulating and not platform_is_removed(driver):
+        print("FAILURE - Cannot start tests with platform on the carrier")
+        return
+
+    test_limit_switches_per_direction(
+        driver, StackerAxis.X, Direction.EXTENT, report, section
+    )
+
+    if not driver._simulating:
+        ui.get_user_ready("Place the platform on the X carrier")
+
+    test_platform_sensors_for_direction(driver, Direction.EXTENT, report, section)
+
+    test_limit_switches_per_direction(
+        driver, StackerAxis.X, Direction.RETRACT, report, section
+    )
+
+    test_platform_sensors_for_direction(driver, Direction.RETRACT, report, section)

hardware-testing/hardware_testing/modules/flex_stacker_evt_qc/test_z_axis.py

@@ -0,0 +1,34 @@
+"""Test Z Axis."""
+from typing import List, Union
+from hardware_testing.data.csv_report import (
+    CSVReport,
+    CSVLine,
+    CSVLineRepeating,
+    CSVResult,
+)
+
+from .utils import test_limit_switches_per_direction
+from .driver import FlexStacker, StackerAxis, Direction
+
+
+def build_csv_lines() -> List[Union[CSVLine, CSVLineRepeating]]:
+    """Build CSV Lines."""
+    return [
+        CSVLine(
+            "limit-switch-trigger-positive-untrigger-negative", [bool, bool, CSVResult]
+        ),
+        CSVLine(
+            "limit-switch-trigger-negative-untrigger-positive", [bool, bool, CSVResult]
+        ),
+    ]
+
+
+def run(driver: FlexStacker, report: CSVReport, section: str) -> None:
+    """Run."""
+    test_limit_switches_per_direction(
+        driver, StackerAxis.Z, Direction.EXTENT, report, section
+    )
+
+    test_limit_switches_per_direction(
+        driver, StackerAxis.Z, Direction.RETRACT, report, section
+    )