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fix(focas): decode servo/spindle meters by their base/exponent envelope; MaxRpm -> MotorSpeedPct

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Servo (0x0056) and spindle (0x0040) meter records are 8 bytes:
[i32 value][u16 base][u16 exponent], the same self-describing envelope as the
position blocks.

Servo: offset 4 was read as a decimal count. It is the BASE (a steady 10), so
every load was divided by 10^10 and published ~0 -- the sister ignitionoee panel
read servo 0% on every axis of a Makino cutting at 20,000 rpm. Loads are now
value / base^exponent, a direct percentage.

Spindle: the raw meter is a 1/16384 fraction of full scale. Settled on the real
Z-34184 by regressing the type-1 meter against cnc_rddynamic2 spindle speed over
596..20,000 rpm (rpm = 1.220749 x meter; 16384 x 1.220749 = 20000.75). So:
- Spindle/{name}/Load publishes % of rated load (Float64; was the raw Int32
  count -- a reading of 9155 meant 55.9%).
- Spindle/{name}/MaxRpm is RENAMED Spindle/{name}/MotorSpeedPct (Float64, % of
  maximum speed) and is polled with Load. The old node was actively wrong: the
  type-1 meter is the live motor speed, and it was read once at bootstrap and
  served forever as if it were a max-RPM constant. Client-visible: FIXED: tags
  on .../MaxRpm must be re-pointed.
- The spindle read no longer stops at the first zero after slot 1 (which dropped
  an idle second spindle and kept non-zero residue); every slot is returned.

A record whose envelope is undescribable (base not 2/10, exponent > 18 -- e.g.
residue past the configured axis/spindle count) publishes BadNoData, never a Good 0.

Ported from the sister ignitionoee FOCAS driver v0.17.2/v0.17.3 (Focas.Wire-019);
live captures live-spmeter-{load,maxrpm}-0x0040.bin added as fixtures.
This commit is contained in:
Joseph Doherty
2026-10-07 14:07:22 -04:00
parent 69e0a622f3
commit 1dba46bd7b
13 changed files with 518 additions and 123 deletions
Download Patch File Download Diff File Expand all files Collapse all files
src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/Wire/FocasWireClient.cs
+47 -26
View File
@@ -420,12 +420,15 @@ public sealed class FocasWireClient : IAsyncDisposable, IDisposable
return new FocasResult<IReadOnlyList<WireServoMeter>>(rc, result);
}
/// <summary>Read per-spindle load percentages via <c>cnc_rdspload</c> (command <c>0x0040</c> with arg1=0).</summary>
/// <summary>
/// Read the per-spindle load meter via <c>cnc_rdspmeter</c> (command <c>0x0040</c>, type 0).
/// <see cref="WireSpindleMetric.Percent"/> is % of rated load (16384 = 100%).
/// </summary>
/// <param name="spindleSelector">Spindle selector; -1 selects all spindles.</param>
/// <param name="cancellationToken">Cancellation token for the read operation.</param>
/// <param name="timeout">Optional per-call timeout override.</param>
/// <param name="pathId">Optional path ID override; defaults to <see cref="PathId"/>.</param>
/// <returns>The per-spindle load percentages, wrapped in a <see cref="FocasResult{T}"/>.</returns>
/// <returns>The per-spindle load meters, wrapped in a <see cref="FocasResult{T}"/>.</returns>
public Task<FocasResult<IReadOnlyList<WireSpindleMetric>>> ReadSpindleLoadAsync(
short spindleSelector = -1,
CancellationToken cancellationToken = default,
@@ -433,13 +436,19 @@ public sealed class FocasWireClient : IAsyncDisposable, IDisposable
ushort? pathId = null)
=> ReadSpindleMetricAsync(0, spindleSelector, cancellationToken, timeout, pathId);
/// <summary>Read per-spindle maximum RPMs via <c>cnc_rdspmaxrpm</c> (command <c>0x0040</c> with arg1=1).</summary>
/// <summary>
/// Read the per-spindle motor-speed meter via <c>cnc_rdspmeter</c> (command <c>0x0040</c>,
/// type 1 — historically labelled <c>cnc_rdspmaxrpm</c>). It is NOT a maximum-RPM constant:
/// it is the live motor speed as a fraction of maximum, <see cref="WireSpindleMetric.Percent"/>
/// (a regression against <c>cnc_rddynamic2</c> spindle speed on a real 31i-B gives
/// <c>rpm = 1.220749 × meter</c>, i.e. 16384 = the spindle's 20,000 rpm maximum).
/// </summary>
/// <param name="spindleSelector">Spindle selector; -1 selects all spindles.</param>
/// <param name="cancellationToken">Cancellation token for the read operation.</param>
/// <param name="timeout">Optional per-call timeout override.</param>
/// <param name="pathId">Optional path ID override; defaults to <see cref="PathId"/>.</param>
/// <returns>The per-spindle maximum RPMs, wrapped in a <see cref="FocasResult{T}"/>.</returns>
public Task<FocasResult<IReadOnlyList<WireSpindleMetric>>> ReadSpindleMaxRpmAsync(
/// <returns>The per-spindle motor-speed meters, wrapped in a <see cref="FocasResult{T}"/>.</returns>
public Task<FocasResult<IReadOnlyList<WireSpindleMetric>>> ReadSpindleMotorSpeedAsync(
short spindleSelector = -1,
CancellationToken cancellationToken = default,
TimeSpan? timeout = null,
@@ -771,13 +780,27 @@ public sealed class FocasWireClient : IAsyncDisposable, IDisposable
callTimeout.Token,
new RequestBlock(0x0040, metric, spindleSelector, PathId: EffectivePathId(pathId))).ConfigureAwait(false);
return ToResult<IReadOnlyList<WireSpindleMetric>>(block, payload =>
{
var values = new List<WireSpindleMetric>();
for (var offset = 0; offset + 8 <= payload.Length; offset += 8)
values.Add(new WireSpindleMetric((short)(values.Count + 1), ReadInt32(payload, offset)));
return values;
});
return ToResult(block, ParseSpindleMetrics);
}
/// <summary>
/// Decode a <c>cnc_rdspmeter</c> (0x0040) payload: 8-byte records of
/// <c>[+0..3] i32 value</c>, <c>[+4..5] u16 base</c>, <c>[+6..7] u16 exponent</c>, one per
/// slot of a fixed multi-slot buffer (slots past the spindle count are residue and decode
/// as <see cref="WireSpindleMetric.IsValid"/> = false). Every slot is returned, in wire order.
/// </summary>
/// <param name="payload">The response-block payload.</param>
/// <returns>The per-slot meters.</returns>
internal static IReadOnlyList<WireSpindleMetric> ParseSpindleMetrics(byte[] payload)
{
var values = new List<WireSpindleMetric>();
for (var offset = 0; offset + 8 <= payload.Length; offset += 8)
values.Add(new WireSpindleMetric(
(short)(values.Count + 1),
ReadInt32(payload, offset),
BinaryPrimitives.ReadUInt16BigEndian(payload.AsSpan(offset + 4, 2)),
BinaryPrimitives.ReadUInt16BigEndian(payload.AsSpan(offset + 6, 2))));
return values;
}
private async Task<FocasResult<T>> ReadSingleAsync<T>(
@@ -958,18 +981,16 @@ public sealed class FocasWireClient : IAsyncDisposable, IDisposable
payload.Length >= 8 ? BinaryPrimitives.ReadInt32LittleEndian(payload.AsSpan(4, 4)) : 0);
/// <summary>
/// Decode a <c>cnc_rdsvmeter</c> response into <see cref="WireServoMeter"/> records. On the
/// 31i-B (v3) each per-axis LOADELM is <b>8 bytes</b> — {int32 data; int16 dec; int16 unit}
/// — NOT the 12-byte shape the original parser assumed. The 12-byte stride misaligned after
/// the first record (it read the dec/unit shorts of the prior record as the next record's
/// data → wild values like 655360). Axis NAMES are not in the svmeter payload; they come
/// from the <c>cnc_rdaxisname</c> (0x0089) block requested alongside it and are correlated
/// by index. Validated against a live 31i-B 2026-06-25.
/// <para><b>Scaling caveat:</b> downstream applies LoadPercent = data / 10^dec; on the 31i-B
/// <c>dec</c> read as 10, which makes idle loads vanishingly small. The data/dec/unit field
/// semantics for servo load are inferred from the wire and not yet confirmed against the
/// machine's servo-meter screen — confirm magnitude at commissioning. The alignment + name
/// fix here is what removes the gross misaligned garbage.</para>
/// Decode a <c>cnc_rdsvmeter</c> response into <see cref="WireServoMeter"/> records. Each
/// per-axis record is <b>8 bytes</b> — <c>[+0..3] i32 value</c>, <c>[+4..5] u16 base</c>,
/// <c>[+6..7] u16 exponent</c> — the same self-describing envelope as the position blocks,
/// so the load is <c>value / base^exponent</c>, a direct percentage. (A 12-byte stride
/// misaligned after the first record; reading offset 4 as a decimal count divided every load
/// by 10^10 — both fixed against live 31i-B captures, the latter by the sister ignitionoee
/// driver, Focas.Wire-019.) Axis NAMES are not in the svmeter payload; they come from the
/// <c>cnc_rdaxisname</c> (0x0089) block requested alongside it and are correlated by index.
/// The payload is a fixed 32-slot buffer: slots past the controlled-axis count are residue
/// and decode as <see cref="WireServoMeter.IsValid"/> = false.
/// </summary>
/// <param name="svPayload">The raw <c>cnc_rdsvmeter</c> response payload.</param>
/// <param name="axisNamePayload">The raw <c>cnc_rdaxisname</c> response payload used to correlate axis names by index.</param>
@@ -989,8 +1010,8 @@ public sealed class FocasWireClient : IAsyncDisposable, IDisposable
(short)(index + 1),
name,
ReadInt32(svPayload, offset),
ReadInt16(svPayload, offset + 4),
ReadInt16(svPayload, offset + 6)));
BinaryPrimitives.ReadUInt16BigEndian(svPayload.AsSpan(offset + 4, 2)), // BASE, not a decimal
BinaryPrimitives.ReadUInt16BigEndian(svPayload.AsSpan(offset + 6, 2))));
}
return result;
}