diff --git a/docs/drivers/FOCAS.md b/docs/drivers/FOCAS.md index f9b4cb28..35daeb93 100644 --- a/docs/drivers/FOCAS.md +++ b/docs/drivers/FOCAS.md @@ -244,6 +244,13 @@ control's raw codes, published verbatim as Int32 so a client sees exactly what t | `Edit`, `TmMode` | program-edit state; T/M mode | Author one the same way as any fixed-tree tag — `FIXED:Status/Run` (Int32), `FIXED:Status/RunText` (String). +Live (hw2 gate, 2026-10-08, Makino Z-34184 31i-B, idle): `cnc_statinfo` answers a 14-byte primary block and read +steadily `Auto=3 Run=0 (RESET) Motion=0 Mstb=0 Emergency=0 Alarm=0 Edit=0 TmMode=0` over 6 minutes, with an empty +`cnc_rdalmmsg2` list — consistent. ⚠️ `Auto=3` (EDIT on the table above) disagrees with `OperationMode/ModeText`, +which read `AUTO` (`cnc_rdopmode` 0x0057 = 1) throughout; ignitionoee independently found 0x0057 toggling 1↔2 with +no explained meaning on the same machine, so treat `OperationMode/` as unconfirmed on the 31i-B and confirm `Auto` +against the panel before relying on either. + Like `Program/`, the subtree is gated on a bootstrap probe: a control that refuses `cnc_statinfo` gets no `Status/` nodes and the rest of the tree is unaffected. Reads are served from the poll snapshot, so they issue no wire traffic and go `BadCommunicationError` once the device has stopped answering. @@ -317,12 +324,19 @@ FANUC signal map: | Signal | PMC address | Notes | |---|---|---| -| Feed override `*FV0-*FV7` | `G12` (Byte) | **Inverted**: the byte holds the one's complement. Percent = `255 - value` for a binary-coded switch (`255` = 0%, `155` = 100%); gray-coded/ladder-converted panels differ | +| Feed override `*FV0-*FV7` | `G12` (Byte) | **Inverted**: the byte holds the one's complement. Percent = `~value & 0xFF` for a binary-coded switch (raw `0xFF` = 0%, raw `0x9B` = 100%); gray-coded/ladder-converted panels differ | | Rapid override `ROV1`, `ROV2` | `G14.0`, `G14.1` (Bit) | Two bits select 100% / 50% / 25% / F0 | -| Spindle override `SOV0-SOV7` | `G30` (Byte) | Percent, usually a direct 0-150 value | +| Spindle override `SOV0-SOV7` | `G30` (Byte) | Percent, usually a direct 0-150 value — mask it (`value & 0xFF`): 128-150 % read negative | -Author them as normal PMC tags (`G12`, `G14.0`, `G30` — G is accepted on the 30i family and the 16i). To publish a -percentage rather than the raw byte, derive it with a virtual tag (`255 - ctx.GetTag("{{equip}}/FeedOverrideRaw")`). +Author them as normal PMC tags (`G12`, `G14.0`, `G30` — G is accepted on the 30i family and the 16i). ⚠️ A `Byte` +tag is **signed** (`sbyte`, published as Int32), so a raw byte above `0x7F` reads negative: on the Makino Z-34184 at +100 % feed override `G12` reads **`-101`** (raw `0x9B` = 155). `255 - value` would therefore give 356, not 100 — mask +before inverting. To publish a percentage rather than the raw byte, derive it with a virtual tag +(`~(int)ctx.GetTag("{{equip}}/FeedOverrideRaw").Value & 0xFF` for `G12`; `(int)… & 0xFF` for `G30`). + +Read-only live check (hw2 gate, 2026-10-08, Makino Z-34184 idle at the panel's 100 % positions): `G12 = -101` +(→ 100 %), `G14.0 = G14.1 = false` (→ rapid 100 %), `G30 = 100` (→ 100 %). Plausible against the standard map; +not yet cross-checked against the switches at other positions. ⚠️ **The addresses above are the FANUC *standard* signal assignment; the meaning is defined by the machine builder's ladder.** Confirm each against the machine's own PMC signal list before trusting the number, and @@ -489,6 +503,12 @@ an `ALARM:` address without the `alarm` object (not a condition, and no value to on a non-`ALARM:` address (a condition nothing can raise). Reading an `ALARM:` tag's RawPath through the driver returns `BadNotSupported`; writing it, `BadNotWritable`. +**Live (passive, read-only) — hw2 gate 2026-10-08, Makino Z-34184.** `ALARM:*`, `ALARM:OTHER`, `ALARM:Servo` and +`ALARM:T6` subscribed for 6 minutes at a 2 s poll: the control answered `cnc_rdalmmsg2` `rc=0` with an **empty** +(0-byte) payload every time, no condition event of any kind was raised (no spurious Raise, no quality churn), and driver +health stayed Healthy. With no alarm active, the 76-vs-80-byte layout and the 30i type codes remain unobserved on +this control. + **Known residuals.** Whether the alarm *list* itself flickers at a CNC reset (the status word does, one poll) is unobserved; if the live gate shows it, a clear-debounce knob is the follow-up. Real-machine raise/clear is only observable passively — never induce an alarm on a production control. diff --git a/src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/FocasDriver.cs b/src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/FocasDriver.cs index 54d97740..673b271f 100644 --- a/src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/FocasDriver.cs +++ b/src/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS/FocasDriver.cs @@ -1816,41 +1816,60 @@ public sealed class FocasDriver : IDriver, IReadable, IWritable, ITagDiscovery, { if (device.Client is { IsConnected: true } c) return c; - // 05/STAB-8: inside an open backoff window a data-path / per-tick-loop caller fails fast — no - // socket create, no wire connect. The probe loop bypasses this and drives failure/success. - if (!bypassBackoff && !device.Backoff.ShouldAttempt(DateTime.UtcNow)) - throw new ConnectionThrottledException( - $"FOCAS connect to {device.Options.HostAddress} throttled — backoff window open after a recent connect failure."); - - // Discard the existing client (if any) before creating a new one. A client that is - // non-null but not connected may have been disposed by a HandleRecycle race or a prior - // teardown — retrying ConnectAsync on a disposed FocasWireClient hits ThrowIfDisposed and - // returns a permanent BadCommunicationError with no recovery. Replacing it unconditionally - // ensures EnsureConnectedAsync always works with a fresh, non-disposed instance. - if (device.Client is not null) - { - device.Client.Dispose(); - device.Client = null; - } - - // Wrap the raw wire client so every operation on the device's single FOCAS/2 socket is - // serialized (request→response on one socket cannot interleave) and time-bounded. Without - // this, the equipment poll, fixed-tree loop, probe, and recycle loop collide on the shared - // socket and a stalled read blocks forever — leaving bound tags at BadWaitingForInitialData. - device.Client = new SynchronizedFocasClient(_clientFactory.Create(), _options.Timeout); + // Serialize the connect (hw2 Makino live gate, 2026-10-08). The alarm poll loop and the fixed-tree loop + // both reach here right after init; unserialized, the second caller saw the first caller's still- + // CONNECTING client as "not connected", disposed it and opened a second session, and the first caller's + // failure path then disposed the second caller's client — two sessions to a CNC with a small handle pool, + // a disposed client handed back, and a spurious backoff failure (observed live as the fixed-tree + // bootstrap failing with ObjectDisposedException: FocasWireClient). + await device.ConnectGate.WaitAsync(ct).ConfigureAwait(false); try { - await device.Client.ConnectAsync(device.ParsedAddress, _options.Timeout, ct).ConfigureAwait(false); + // Another caller may have connected while this one waited. + if (device.Client is { IsConnected: true } connected) return connected; + + // 05/STAB-8: inside an open backoff window a data-path / per-tick-loop caller fails fast — no + // socket create, no wire connect. The probe loop bypasses this and drives failure/success. + if (!bypassBackoff && !device.Backoff.ShouldAttempt(DateTime.UtcNow)) + throw new ConnectionThrottledException( + $"FOCAS connect to {device.Options.HostAddress} throttled — backoff window open after a recent connect failure."); + + // Discard the existing client (if any) before creating a new one. A client that is + // non-null but not connected may have been disposed by a HandleRecycle race or a prior + // teardown — retrying ConnectAsync on a disposed FocasWireClient hits ThrowIfDisposed and + // returns a permanent BadCommunicationError with no recovery. Replacing it unconditionally + // ensures EnsureConnectedAsync always works with a fresh, non-disposed instance. + if (device.Client is not null) + { + device.Client.Dispose(); + device.Client = null; + } + + // Wrap the raw wire client so every operation on the device's single FOCAS/2 socket is + // serialized (request→response on one socket cannot interleave) and time-bounded. Without + // this, the equipment poll, fixed-tree loop, probe, and recycle loop collide on the shared + // socket and a stalled read blocks forever — leaving bound tags at BadWaitingForInitialData. + var client = new SynchronizedFocasClient(_clientFactory.Create(), _options.Timeout); + device.Client = client; + try + { + await client.ConnectAsync(device.ParsedAddress, _options.Timeout, ct).ConfigureAwait(false); + } + catch (Exception ex) + { + // Dispose only OUR client — never one another path installed meanwhile (recycle/teardown). + client.Dispose(); + if (ReferenceEquals(device.Client, client)) device.Client = null; + // The caller's OWN cancellation says nothing about the CNC: do not open the backoff window, or + // every caller queued on ConnectGate behind it would be throttled for ~1 s for nothing. + if (!(ex is OperationCanceledException && ct.IsCancellationRequested)) + device.Backoff.RecordFailure(DateTime.UtcNow); // 05/STAB-8: open the backoff window + throw; + } + device.Backoff.RecordSuccess(); // 05/STAB-8: recovery resets the window immediately + return client; } - catch - { - device.Client.Dispose(); - device.Client = null; - device.Backoff.RecordFailure(DateTime.UtcNow); // 05/STAB-8: open the backoff window - throw; - } - device.Backoff.RecordSuccess(); // 05/STAB-8: recovery resets the window immediately - return device.Client; + finally { device.ConnectGate.Release(); } } /// Disposes the driver and releases all resources synchronously. @@ -1919,13 +1938,17 @@ public sealed class FocasDriver : IDriver, IReadable, IWritable, ITagDiscovery, /// Per-device connect-attempt throttle (05/STAB-8). A dead CNC fails fast inside the /// backoff window instead of paying a full two-socket reconnect on every tick of each of /// the read / write / probe / fixed-tree / recycle loops; the probe loop bypasses it and a - /// successful connect resets it. FOCAS's EnsureConnectedAsync is not gate-serialized - /// (the loops already race the client swap by design), so this is best-effort — atomic - /// enough on 64-bit for the int/DateTime state, and a benign extra/skipped attempt is the - /// worst outcome of a race. + /// successful connect resets it. The connect itself is serialized by + /// ; the backoff is consulted inside it. /// public ConnectionBackoff Backoff { get; } = new(TimeSpan.FromSeconds(1), TimeSpan.FromSeconds(30)); + /// + /// Serializes EnsureConnectedAsync per device, so concurrent loops (alarm poll, fixed tree, data + /// path) share ONE connect instead of racing two sessions and disposing each other's client. + /// + public SemaphoreSlim ConnectGate { get; } = new(1, 1); + /// Gets the lock object for probe synchronization. public object ProbeLock { get; } = new(); /// Gets or sets the current host connectivity state. diff --git a/tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS.Tests/FocasConcurrentConnectTests.cs b/tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS.Tests/FocasConcurrentConnectTests.cs new file mode 100644 index 00000000..a92b195c --- /dev/null +++ b/tests/Drivers/ZB.MOM.WW.OtOpcUa.Driver.FOCAS.Tests/FocasConcurrentConnectTests.cs @@ -0,0 +1,132 @@ +using Shouldly; +using Xunit; +using ZB.MOM.WW.OtOpcUa.Core.Abstractions; +using ZB.MOM.WW.OtOpcUa.Driver.FOCAS; + +namespace ZB.MOM.WW.OtOpcUa.Driver.FOCAS.Tests; + +/// +/// Two callers reaching EnsureConnectedAsync while the device has no live session (the alarm poll loop +/// and the fixed-tree loop both start right after init) must open ONE session between them. Found live on the +/// Makino Z-34184 (hw2 gate, 2026-10-08): the fixed-tree bootstrap failed with +/// ObjectDisposedException: FocasWireClient, because the second caller saw the first caller's +/// still-connecting client as "not connected", disposed it, and opened a second one — and the first caller's +/// failure path then disposed the SECOND caller's client. Two TCP sessions to a production CNC with a small +/// handle pool, a disposed client handed back to a caller, and a spurious connect-backoff failure. +/// +[Trait("Category", "Unit")] +public sealed class FocasConcurrentConnectTests +{ + /// A fake whose connect parks until released, and which — like the real wire client — refuses to + /// finish connecting once disposed. + private sealed class GatedConnectClient(Task release, TaskCompletionSource? entered = null) : FakeFocasClient + { + private bool _disposed; + + public override async Task ConnectAsync(FocasHostAddress address, TimeSpan timeout, CancellationToken ct) + { + entered?.TrySetResult(); + await release.WaitAsync(ct); + if (_disposed) throw new ObjectDisposedException("FocasWireClient"); + await base.ConnectAsync(address, timeout, ct); + } + + public override void Dispose() + { + _disposed = true; + base.Dispose(); + } + } + + /// Concurrent first reads share one connect; nobody's client is disposed under them. + [Fact] + public async Task Concurrent_first_reads_open_one_session_and_both_succeed() + { + var release = new TaskCompletionSource(TaskCreationOptions.RunContinuationsAsynchronously); + var entered = new TaskCompletionSource(TaskCreationOptions.RunContinuationsAsynchronously); + var factory = new FakeFocasClientFactory { Customise = () => new GatedConnectClient(release.Task, entered) }; + await using var drv = new FocasDriver(new FocasDriverOptions + { + Devices = [new FocasDeviceOptions("focas://10.0.0.5:8193")], + RawTags = FocasRawTags.Entries([ + new FocasTagDefinition("A", "focas://10.0.0.5:8193", "R100", FocasDataType.Byte), + new FocasTagDefinition("B", "focas://10.0.0.5:8193", "R200", FocasDataType.Byte)]), + Probe = new FocasProbeOptions { Enabled = false }, + Timeout = TimeSpan.FromSeconds(5), + }, "drv-1", factory); + await drv.InitializeAsync("{}", CancellationToken.None); + + var first = drv.ReadAsync(["A"], CancellationToken.None); + // Deterministic: the first caller is now parked INSIDE its connect (client created, not yet connected) — + // the exact window the race needs. The second caller then runs synchronously up to its first real await: + // pre-fix that is "dispose the first client, Create() a second"; with the gate it parks on ConnectGate. + await entered.Task.WaitAsync(TimeSpan.FromSeconds(5)); + var second = drv.ReadAsync(["B"], CancellationToken.None); + release.SetResult(); + var results = await Task.WhenAll(first, second); + + factory.Clients.Count.ShouldBe(1, "two concurrent callers must share one FOCAS session, not race two"); + factory.Clients[0].DisposeCount.ShouldBe(0, "no caller may dispose a client another caller is using"); + results[0].Single().StatusCode.ShouldBe(FocasStatusMapper.Good); + results[1].Single().StatusCode.ShouldBe(FocasStatusMapper.Good); + } + + /// A failed connect does not poison a later one — the gate is released on failure. + [Fact] + public async Task A_failed_connect_releases_the_gate_for_the_next_caller() + { + var factory = new FakeFocasClientFactory(); + var attempt = 0; + factory.Customise = () => new FakeFocasClient { ThrowOnConnect = Interlocked.Increment(ref attempt) == 1 }; + await using var drv = new FocasDriver(new FocasDriverOptions + { + Devices = [new FocasDeviceOptions("focas://10.0.0.5:8193")], + RawTags = FocasRawTags.Entries([new FocasTagDefinition("A", "focas://10.0.0.5:8193", "R100", FocasDataType.Byte)]), + Probe = new FocasProbeOptions { Enabled = false }, + }, "drv-1", factory); + await drv.InitializeAsync("{}", CancellationToken.None); + + (await drv.ReadAsync(["A"], CancellationToken.None)).Single().StatusCode + .ShouldNotBe(FocasStatusMapper.Good); + // Past the 1 s initial connect backoff window, the next caller must be able to connect. + await Task.Delay(TimeSpan.FromMilliseconds(1100)); + var read = drv.ReadAsync(["A"], CancellationToken.None); + (await read.WaitAsync(TimeSpan.FromSeconds(5))).Single().StatusCode.ShouldBe(FocasStatusMapper.Good); + } + + /// + /// A caller cancelled during its connect must not open the backoff window: the cancellation is the caller's, + /// not the CNC's, and a recorded failure would throttle every caller queued behind it on the gate. + /// + [Fact] + public async Task A_caller_cancelled_during_connect_does_not_throttle_the_next_caller() + { + var never = new TaskCompletionSource(TaskCreationOptions.RunContinuationsAsynchronously); + var entered = new TaskCompletionSource(TaskCreationOptions.RunContinuationsAsynchronously); + var factory = new FakeFocasClientFactory(); + var created = 0; + // First client parks in connect until cancelled; every later client connects immediately. + factory.Customise = () => Interlocked.Increment(ref created) == 1 + ? new GatedConnectClient(never.Task, entered) + : new FakeFocasClient(); + await using var drv = new FocasDriver(new FocasDriverOptions + { + Devices = [new FocasDeviceOptions("focas://10.0.0.5:8193")], + RawTags = FocasRawTags.Entries([new FocasTagDefinition("A", "focas://10.0.0.5:8193", "R100", FocasDataType.Byte)]), + Probe = new FocasProbeOptions { Enabled = false }, + Timeout = TimeSpan.FromSeconds(5), + }, "drv-1", factory); + await drv.InitializeAsync("{}", CancellationToken.None); + + using var cts = new CancellationTokenSource(); + var cancelled = drv.ReadAsync(["A"], cts.Token); + await entered.Task.WaitAsync(TimeSpan.FromSeconds(5)); + cts.Cancel(); + try { await cancelled; } catch (OperationCanceledException) { /* either surfaced or mapped — both fine */ } + + // Immediately — well inside the 1 s initial backoff window a recorded failure would have opened. + var next = await drv.ReadAsync(["A"], CancellationToken.None).WaitAsync(TimeSpan.FromSeconds(5)); + next.Single().StatusCode.ShouldBe(FocasStatusMapper.Good, "a caller's own cancellation must not throttle the next connect"); + factory.Clients.Count.ShouldBe(2); + } +}