diff --git a/.github/workflows/ci.yml b/.github/workflows/ci.yml index 3c909cc6..88a8c5ab 100644 --- a/.github/workflows/ci.yml +++ b/.github/workflows/ci.yml @@ -40,6 +40,10 @@ jobs: run: pip install -U platformio - name: Audio pack tests run: python3 scripts/test_audio_pack.py + - name: PCBA host tests + run: python3 scripts/test_pcba_test.py + - name: PCBA web tests + run: node scripts/test_pcba_web.mjs - name: Laptop screen inserts PDF up to date run: python3 scripts/laptop_screens.py --check - name: Build firmware @@ -59,6 +63,8 @@ jobs: if-no-files-found: error - name: Build OLED expression demo run: pio run -e expression-demo + - name: Build PCBA test image + run: pio run -e pcba-test - name: Host Unity tests run: pio test -e native diff --git a/.gitignore b/.gitignore index 3b388a31..d4d4dac6 100644 --- a/.gitignore +++ b/.gitignore @@ -4,6 +4,8 @@ data/*.* data/*/ artifacts/ +.venv + node_modules/ *.bak diff --git a/docs/README.md b/docs/README.md index 37af5a18..21ff8dae 100644 --- a/docs/README.md +++ b/docs/README.md @@ -16,6 +16,7 @@ Pick a path. Depth lives in the linked pages. | **Print / parts inventory** | [../3d_models/README.md](../3d_models/README.md) | | **Order printed parts** (no 3D printer) | [3d/order-parts.md](3d/order-parts.md) | | **Order main control board** (PCB / PCBA) | [hardware/order-main-control-board.md](hardware/order-main-control-board.md) | +| **Test a produced board** (PCBA, rev 3) | [hardware/pcba-test.md](hardware/pcba-test.md) | | **Adapt CAD to a different servo** | [3d/parametric-design.md](3d/parametric-design.md) | | **Add a new CAD / printable part** | [3d/adding-parts.md](3d/adding-parts.md) | | **Optional mods** | [../mods/README.md](../mods/README.md) | diff --git a/docs/hardware/pcba-test.md b/docs/hardware/pcba-test.md new file mode 100644 index 00000000..cbd45914 --- /dev/null +++ b/docs/hardware/pcba-test.md @@ -0,0 +1,102 @@ +# PCBA test + +Check a produced main control board rev 3 with a golden ESP32-C3-Zero and one operator. The test is compatible with main control board rev 3. The product firmware cannot do this check. Power is the USB cable through the module. No servo supply. + +The golden module stays with the tester. The ESP32 must already run the test firmware. How to get one is below. Do not ship that module on a board. + +## Get an ESP32 with the test firmware + +The ESP32 must already run the test firmware. The product firmware cannot run this test. The script and the page do not flash the module. + +Seat a Waveshare ESP32-C3-Zero on a main control board. Match the USB mark. Plug a USB-C data cable into the board socket, not the ESP32 socket. From the repo root: + +```bash +pio run -e pcba-test -t upload +``` + +When the test firmware is running, the onboard LED stays steady white. That lamp is not a board pass or fail. Before a module leaves the bench, flash the product image again. + +The module LED stays steady white while the test image has power, including after a failed PCA probe, a verdict, and `q`. Steady white means the test image is running. It is not the board verdict. Judge the board by the ear on J1 and the plug lamps. Unplugging USB is what turns the module LED off. + +## Run the script + +Python 3 and pyserial. From the repo root: + +```bash +python3 -m pip install pyserial +python3 scripts/pcba_test.py +``` + +The script prints a header, the web tester address, and a prepare card. It opens the board USB port. If that port is busy, the script says so and waits. Close the other program using the board. Keys match the page: Enter accepts a step, `n` rejects it. On SPEAKER, `+` is louder and `-` is quieter. After `RESULT`, unplug USB for the next board, or `q` to stop. + +The other path is the web tester: [https://tinyengineer.dev/pcba_test](https://tinyengineer.dev/pcba_test). Chrome or Edge only. If the browser cannot open a serial port, the page says so and names `python3 scripts/pcba_test.py`. + +USB-C data cable. Speaker on J1. Cards stay on screen. Act on the latest one. + +## Testing board + +The testing board seats on one column at a time. The silk-side pin is yellow (SIG). The middle pin is red (5 V). Treat the square pad as GND. + +During `servos`, signal is on all five servo outputs. Take the testing board and plug it into one column at a time: HEAD, NECK, ARM L, ARM R, and BODY. On every column, red stays on and yellow pulses. + +## What you see + +The first card is prepare. Do that, then connect the board. The next card waits until the board is on USB, then waits for Enter before the first test step. + +1. Take the board. +2. Plug in the ESP32. Match the USB mark on the board. +3. Plug the speaker into the JST speaker port. +4. Connect USB to the board. Use the board socket, not the ESP32. + +Power-on is a short beep-beep, then silence. The next card is: + +``` +CONNECTED + +The board is connected. + +Enter = continue +``` + +Enter starts step `1/3`. `n` rejects a step. On a test step that is `Enter = good` and `n = bad`. On SPEAKER, `+` is louder and `-` is quieter. The card shows `+ = louder` and `- = quieter`, plus the level, from `Volume 1/10` through `Volume 10/10`. The tone keeps playing. + +| Card | What you do | Look | +| --- | --- | --- | +| `1/3` `tone` | Speaker on the JST speaker port. `+` louder, `-` quieter. | A repeating tone until Enter or `n`. | +| `2/3` `servos` | Signal is on all five servo outputs. Plug the testing board into one column at a time: HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. | Red stays on and yellow pulses. | +| `3/3` OE OUTPUT ENABLE | Look at the testing board on one column. No need to test each servo column. | The red LED stays on. Only the yellow LED goes out. | + +A column whose yellow LED does not pulse is a failure. Judge every column before Enter. + +## Keys + +`n` shows `FAIL` and the menu `r`, `c`, `a`. + +- `r` retries the step and drops that failure. On screen: `r = try this step again`. +- `c` keeps the failure and goes on. On screen: `c = keep the fail, go on`. +- `a` clears the board and returns to CONNECTED without unplugging. Enter starts the test again. On screen: `a = start this board over`. + +After `RESULT PASS` or `RESULT FAIL`, the card says to unplug USB for the next board, or `q` to stop. The host stays open and attaches when the port returns. `q` prints `STOP`. `n` after the verdict does nothing. + +`RESULT PASS` covers the speaker, the five servo columns, and output enable. It does not cover J2, J3, J4, the OLED, Wi-Fi, or a 2 A load. A fault in those can still be present. + +No PCA answer prints `FAIL pca` and `RESULT FAIL pca`. The card says the PCA9685 did not answer and this board fails before the speaker test. There is no `r` / `c` / `a` for that failure. Unplug or `q`, same as any other verdict. + +## Dialogue + +The wire under each card is a short token. All accepted: + +``` +STEP tone +STEP servos +STEP oe +RESULT PASS +``` + +`tone` and `servos` rejected with `c`: + +``` +FAIL tone +FAIL servos +RESULT FAIL tone servos +``` diff --git a/docs/hardware/testing.md b/docs/hardware/testing.md index 22884aa9..239e6458 100644 --- a/docs/hardware/testing.md +++ b/docs/hardware/testing.md @@ -1,5 +1,7 @@ # Hardware testing +A produced main control board is checked with the [PCBA session](pcba-test.md), not this product boot. The golden module stays with the tester. + Firmware is [`src/main.cpp`](../../src/main.cpp). Boot **inits** hardware and starts HTTP. Demos (OLED, tones, servo sweep) run on demand via REST. Helpers: - [`src/hardware/rgb.cpp`](../../src/hardware/rgb.cpp) diff --git a/docs/testing.md b/docs/testing.md index 761d6338..1ccb71f8 100644 --- a/docs/testing.md +++ b/docs/testing.md @@ -22,9 +22,12 @@ node scripts/expressions/generate.js --check node scripts/expressions/test-assets.js pio test -e native pio run -e expression-demo +pio run -e pcba-test +python3 scripts/test_pcba_test.py +node scripts/test_pcba_web.mjs ``` -The `expression-demo` environment builds a separate OLED-only application without changing the default robot build. For a later bench test, follow its [wiring and upload notes](../lib/TinyEngineerExpressions/README.md#standalone-oled-demo), leave the separate servo supply off, and observe all 16 faces through a complete 48-second cycle. Report physical display results separately from host tests and compilation. +The `expression-demo` environment builds a separate OLED-only application without changing the default robot build. `pcba-test` builds the PCBA session the same way. Bench steps: [hardware/pcba-test.md](hardware/pcba-test.md). For a later expression-demo bench test, follow the [wiring and upload notes](../lib/TinyEngineerExpressions/README.md#standalone-oled-demo), leave the separate servo supply off, and observe all 16 faces through a complete 48-second cycle. Report physical display results separately from host tests and compilation. ## Web UI diff --git a/examples/pcba-test/main.cpp b/examples/pcba-test/main.cpp new file mode 100644 index 00000000..2d101cbd --- /dev/null +++ b/examples/pcba-test/main.cpp @@ -0,0 +1,451 @@ +#include +#include +#include +#include +#include +#include + +#include "pins.h" +#include "servos.h" + +// PCBA session on the golden module. Product src/ is not linked. + +namespace { + +constexpr uint16_t kFullOff = 4096; +constexpr int kToneLowHz = 500; +constexpr int kToneHighHz = 750; +constexpr int16_t kToneAmplitude = 11000; +// Index 5 is the bench default. Peak of both partials stays inside int16. +constexpr int16_t kToneLevels[] = { + 2000, 4000, 6000, 8000, 9500, 11000, 12500, 14000, 15200, 16300, +}; +constexpr int kToneLevelCount = sizeof(kToneLevels) / sizeof(kToneLevels[0]); +constexpr int kToneLevelDefault = 5; +// 441 frames closes both partials, so the loop junction stays continuous. +constexpr int kToneFrames = 441; + +enum Phase : uint8_t { PhaseStart, PhaseWait, PhaseMenu, PhaseResult, PhaseStop }; + +struct StepDef { + const char* name; + int channel; +}; + +// channel < 0 is the speaker. kAllChannels pulses every servo output together. +// kOeOff releases the PCA9685 outputs while the same pulse keeps running. +constexpr int kAllChannels = -2; +constexpr int kOeOff = -3; + +constexpr StepDef kSteps[] = { + {"tone", -1}, + {"servos", kAllChannels}, + {"oe", kOeOff}, +}; + +constexpr int kStepCount = sizeof(kSteps) / sizeof(kSteps[0]); + +static_assert(kStepCount == 3, "PCBA step list drifted"); +static_assert(kToneLevelCount == 10, "volume card is 1..10"); +static_assert(kToneLevels[kToneLevelDefault] == kToneAmplitude, "default level drifted"); + +I2SClass I2S; +Adafruit_PWMServoDriver pwm(PCA9685_ADDRESS); + +Phase gPhase = PhaseStart; +int gStep = 0; +bool gFailed[kStepCount] = {}; +bool gPcaOk = false; +bool gToneOn = false; +int gToneLevel = kToneLevelDefault; +bool gI2sReady = false; +uint32_t gPulseAt = 0; +uint32_t gPromptAt = 0; +int16_t gTonePcm[kToneFrames * 2]; + +static_assert(kToneFrames * kToneLowHz % SAMPLE_RATE == 0, "low partial must close"); +static_assert(kToneFrames * kToneHighHz % SAMPLE_RATE == 0, "high partial must close"); + +void setOe(bool enabled) { + if (!PCA9685_OE_WIRED) { + return; + } + digitalWrite(PCA9685_OE_PIN, enabled ? LOW : HIGH); +} + +void writeChannel(int channel, bool high) { + if (high) { + pwm.setPWM(channel, kFullOff, 0); + } else { + pwm.setPWM(channel, 0, kFullOff); + } +} + +void allOff() { + for (int channel = 0; channel < SERVO_COUNT; channel++) { + writeChannel(channel, false); + } +} + +void writeDuty(int channel, uint16_t duty) { + if (duty == 0) { + pwm.setPWM(channel, 0, kFullOff); + return; + } + pwm.setPWM(channel, 0, duty); +} + +void servicePulse() { + if (!gPcaOk || (gPhase != PhaseWait && gPhase != PhaseMenu)) { + return; + } + const int channel = kSteps[gStep].channel; + if (channel != kAllChannels && channel != kOeOff) { + return; + } + const uint32_t now = millis(); + if (gPulseAt != 0 && now - gPulseAt < 20) { + return; + } + gPulseAt = now; + constexpr uint32_t kHalf = 500; + const uint32_t t = now % (kHalf * 2); + const uint32_t rise = t < kHalf ? t : (kHalf * 2 - t); + const uint16_t duty = static_cast(rise * 4095 / kHalf); + for (int channel = 0; channel < SERVO_COUNT; channel++) { + writeDuty(channel, duty); + } +} + +bool probePca() { + Wire.beginTransmission(PCA9685_ADDRESS); + return Wire.endTransmission() == 0; +} + +void printResult() { + Serial.print("RESULT "); + bool any = false; + for (int index = 0; index < kStepCount; index++) { + if (gFailed[index]) { + any = true; + break; + } + } + if (!any) { + Serial.println("PASS"); + return; + } + Serial.print("FAIL"); + for (int index = 0; index < kStepCount; index++) { + if (!gFailed[index]) { + continue; + } + Serial.print(' '); + Serial.print(kSteps[index].name); + } + Serial.println(); +} + +void prepareTone(); +void printVolume(); + +void enterStep(int step) { + gStep = step; + gToneOn = false; + const StepDef& def = kSteps[step]; + if (def.channel == kOeOff) { + setOe(false); + gPulseAt = 0; + } else if (def.channel == kAllChannels) { + setOe(true); + gPulseAt = 0; + } else { + setOe(true); + allOff(); + gToneOn = true; + } + Serial.print("STEP "); + Serial.println(def.name); + if (gToneOn) { + printVolume(); + } + gPhase = PhaseWait; +} + +void finishBoard() { + gToneOn = false; + printResult(); + gPhase = PhaseResult; +} + +void acceptStep() { + if (gStep + 1 >= kStepCount) { + finishBoard(); + return; + } + enterStep(gStep + 1); +} + +void failStep() { + gFailed[gStep] = true; + gToneOn = false; + Serial.print("FAIL "); + Serial.println(kSteps[gStep].name); + gPhase = PhaseMenu; +} + +void restartBoard() { + for (int index = 0; index < kStepCount; index++) { + gFailed[index] = false; + } + gToneOn = false; + gStep = 0; + allOff(); + setOe(true); + Serial.println("READY"); + gPhase = PhaseStart; +} + +void printVolume() { + Serial.print("VOL "); + Serial.println(gToneLevel + 1); +} + +void changeVolume(int delta) { + int next = gToneLevel + delta; + if (next < 0) { + next = 0; + } else if (next >= kToneLevelCount) { + next = kToneLevelCount - 1; + } + if (next != gToneLevel) { + gToneLevel = next; + prepareTone(); + } + printVolume(); +} + +void onWaitKey(char key) { + if (key == '\n') { + acceptStep(); + return; + } + if (key == 'n') { + failStep(); + return; + } + if (!gToneOn) { + return; + } + if (key == '+' || key == '=') { + changeVolume(1); + return; + } + if (key == '-') { + changeVolume(-1); + } +} + +void onMenuKey(char key) { + if (key == 'r') { + gFailed[gStep] = false; + enterStep(gStep); + return; + } + if (key == 'c') { + if (gStep + 1 >= kStepCount) { + finishBoard(); + return; + } + enterStep(gStep + 1); + return; + } + if (key == 'a') { + restartBoard(); + } +} + +void onResultKey(char key) { + if (key == '?') { + if (!gPcaOk) { + Serial.println("FAIL pca"); + Serial.println("RESULT FAIL pca"); + } + return; + } + if (key == 'q') { + Serial.println("STOP"); + gPhase = PhaseStop; + } +} + +void onStartKey(char key) { + if (key == '\n') { + enterStep(0); + } +} + +void onKey(char key) { + if (gPhase == PhaseStart) { + onStartKey(key); + } else if (gPhase == PhaseWait) { + onWaitKey(key); + } else if (gPhase == PhaseMenu) { + onMenuKey(key); + } else if (gPhase == PhaseResult) { + onResultKey(key); + } +} + +void pollKeys() { + while (Serial.available() > 0) { + onKey(static_cast(Serial.read())); + } +} + +void prepareTone() { + for (int frame = 0; frame < kToneFrames; frame++) { + const float low = sinf(2.0f * PI * frame * kToneLowHz / SAMPLE_RATE); + const float high = sinf(2.0f * PI * frame * kToneHighHz / SAMPLE_RATE); + float raw = (low + high) * kToneLevels[gToneLevel]; + if (raw > 32767.0f) { + raw = 32767.0f; + } else if (raw < -32767.0f) { + raw = -32767.0f; + } + const int16_t sample = static_cast(raw); + gTonePcm[frame * 2] = sample; + gTonePcm[frame * 2 + 1] = sample; + } +} + +void writeSamples(const int16_t* samples, size_t bytes) { + if (!gI2sReady || bytes == 0) { + return; + } + I2S.write(reinterpret_cast(const_cast(samples)), bytes); +} + +void writeSilenceMs(int ms) { + int16_t zeros[128 * 2] = {}; + int frames = SAMPLE_RATE * ms / 1000; + while (frames > 0) { + const int count = frames > 128 ? 128 : frames; + writeSamples(zeros, static_cast(count) * 2 * sizeof(int16_t)); + frames -= count; + } +} + +void playNote(int hz, int frames) { + constexpr int16_t kChimeAmplitude = 9000; + static int16_t buffer[882 * 2]; + for (int frame = 0; frame < frames; frame++) { + const float raw = sinf(2.0f * PI * frame * hz / SAMPLE_RATE) * kChimeAmplitude; + const int16_t sample = static_cast(raw); + buffer[frame * 2] = sample; + buffer[frame * 2 + 1] = sample; + } + writeSamples(buffer, static_cast(frames) * 2 * sizeof(int16_t)); +} + +void playPowerChime() { + // 40 ms notes a fifth apart. 882 frames closes both. + playNote(800, 882); + writeSilenceMs(20); + playNote(1200, 882); + writeSilenceMs(20); +} + +void serviceTone() { + if (!gToneOn || !gI2sReady || gPhase != PhaseWait) { + return; + } + writeSamples(gTonePcm, sizeof(gTonePcm)); +} + +void startI2s() { + I2S.setPins(I2S_BCLK, I2S_LRC, I2S_DIN); + gI2sReady = I2S.begin( + I2S_MODE_STD, + SAMPLE_RATE, + I2S_DATA_BIT_WIDTH_16BIT, + I2S_SLOT_MODE_STEREO); +} + +void printPrompt() { + if (gPhase == PhaseStart) { + Serial.println("READY"); + } else if (gPhase == PhaseWait) { + Serial.print("STEP "); + Serial.println(kSteps[gStep].name); + } else if (gPhase == PhaseMenu) { + Serial.print("FAIL "); + Serial.println(kSteps[gStep].name); + } +} + +void servicePrompt() { + if (gPhase != PhaseStart && gPhase != PhaseWait && gPhase != PhaseMenu) { + return; + } + const uint32_t now = millis(); + if (gPromptAt != 0 && now - gPromptAt < 200) { + return; + } + gPromptAt = now; + printPrompt(); +} + +void beginSession() { + Serial.println("PCBA-TEST v1"); + Wire.begin(I2C_SDA, I2C_SCL); + gPcaOk = probePca(); + if (!gPcaOk) { + Serial.println("FAIL pca"); + Serial.println("RESULT FAIL pca"); + gPhase = PhaseResult; + return; + } + + pwm.begin(); + pwm.setPWMFreq(200); + allOff(); + setOe(true); + const uint32_t drainUntil = millis() + 50; + while (millis() < drainUntil) { + while (Serial.available() > 0) { + Serial.read(); + } + delay(5); + } + gPhase = PhaseStart; + gToneOn = false; +} + +} // namespace + +void setup() { + // Equal channels stay white for every WS2812 wire order. Leave it on. + constexpr uint8_t kModuleWhite = 64; + rgbLedWrite(RGB_LED_PIN, kModuleWhite, kModuleWhite, kModuleWhite); + + Serial.begin(115200); + if (PCA9685_OE_WIRED) { + pinMode(PCA9685_OE_PIN, OUTPUT); + digitalWrite(PCA9685_OE_PIN, HIGH); + } + startI2s(); + prepareTone(); + playPowerChime(); + beginSession(); +} + +void loop() { + if (gPhase == PhaseStop) { + return; + } + servicePrompt(); + serviceTone(); + servicePulse(); + pollKeys(); +} diff --git a/hardware/boards/main-control-board-servo-tester/main-control-board-servo-tester.kicad_pcb b/hardware/boards/main-control-board-servo-tester/main-control-board-servo-tester.kicad_pcb new file mode 100644 index 00000000..f09d010d --- /dev/null +++ b/hardware/boards/main-control-board-servo-tester/main-control-board-servo-tester.kicad_pcb @@ -0,0 +1,2319 @@ +(kicad_pcb + (version 20260206) + (generator "pcbnew") + (generator_version "10.0") + (general + (thickness 1.6) + (legacy_teardrops no) + ) + (paper "A4") + (layers + (0 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(symbol + (lib_id "power:+3.3V") + (at 128.27 81.28 90) + (unit 1) + (body_style 1) + (exclude_from_sim no) + (in_bom yes) + (on_board yes) + (in_pos_files yes) + (dnp no) + (fields_autoplaced yes) + (uuid "e696bf91-5852-4b79-a1a4-6d0048c88773") + (property "Reference" "#PWR04" + (at 132.08 81.28 0) + (hide yes) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Value" "+3.3V" + (at 124.46 81.2799 90) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + (justify left) + ) + ) + (property "Footprint" "" + (at 128.27 81.28 0) + (hide yes) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Datasheet" "" + (at 128.27 81.28 0) + (hide yes) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (property "Description" "Power symbol creates a global label with name \"+3.3V\"" + (at 128.27 81.28 0) + (hide yes) + (show_name no) + (do_not_autoplace no) + (effects + (font + (size 1.27 1.27) + ) + ) + ) + (pin "1" + (uuid "5f4b097d-ef05-4fdb-ab15-66926edfa416") + ) + (instances + (project "main-control-board-servo-tester" + (path "/b2241bbe-4416-4857-ab8d-09689638c7e6" + (reference "#PWR04") + (unit 1) + ) + ) + ) + ) + (sheet_instances + (path "/" + (page "1") + ) + ) + (embedded_fonts no) +) diff --git a/hardware/boards/main-control-board/main-control-board.kicad_pro b/hardware/boards/main-control-board/main-control-board.kicad_pro index 41d2b771..02593f58 100644 --- a/hardware/boards/main-control-board/main-control-board.kicad_pro +++ b/hardware/boards/main-control-board/main-control-board.kicad_pro @@ -853,7 +853,7 @@ "uuid": "82a78d11-58ff-455c-a94e-f7463ce9fc2e" } ], - "used_designators": "#FLG1-2,#FLG4,PCA2,D1-2,#PWR1-40,J1-8,NT1,MAX2,ESP2,JP1,R1-14,H1-3,USB1,C1-7,U1-4,F1,TP1-5", + "used_designators": "TP1-5,F1,U1-4,C1-7,USB1,H1-3,R1-14,JP1,ESP2,MAX2,NT1,J1-8,#PWR1-40,D1-2,PCA2,#FLG1-2,#FLG4", "variants": [] }, "sheets": [ diff --git a/openspec/changes/archive/2026-10-30-main-control-board-tester/design.md b/openspec/changes/archive/2026-10-30-main-control-board-tester/design.md new file mode 100644 index 00000000..74782ce8 --- /dev/null +++ b/openspec/changes/archive/2026-10-30-main-control-board-tester/design.md @@ -0,0 +1,101 @@ +# Design + +## Context + +See proposal.md for why a PCBA test session exists. The product image in `[env:esp32-c3-devkitm-1]` boots Wi-Fi, HTTP, LittleFS, and the COBS serial stack from `src/main.cpp`. `[env:expression-demo]` already shows the opt-in pattern: its own `main`, a `build_src_filter` that drops `src/`, and none of the product `extra_scripts`. Pin numbers live in `include/pins.h`. Servo columns on U2 are head=0, neck=1, arm-l=2, arm-r=3, body=4, in that physical order from the HEAD silkscreen toward BODY. + +Whoever runs the test uses one golden ESP32-C3-Zero, one 3-pin LED plug (red on the column 5 V pin, blue on PWM), one speaker on J1, and a PC whose OS is not known ahead of time. The script and the page say the test is compatible with main control board rev 3. + +## Goals / Non-Goals + +**Goals:** + +- One opt-in env whose image cannot be produced by the default `pio run`. +- A line protocol the host can follow without parsing COBS. +- Operator keys that sit on the same physical keys on a US and a Polish keyboard. +- Both hosts stay up across USB unplug when the cable moves to the next board. + +**Non-Goals:** + +- Judging the plug LEDs or the speaker from firmware. The operator is the sensor. The onboard LED is only an alive lamp. +- Measuring pulse width, eFuse trip current, or J2/J3/J4. +- A runtime switch inside the product image. +- Serving the tester from the robot `ui/` or from the test image. + +## Decisions + +### Separate env, own main + +`[env:pcba-test]` copies the `expression-demo` shape: same platform, board, and USB CDC flags, `build_src_filter` pointing at `examples/pcba-test/main.cpp`, no `embed_ui`, `copy_assets`, `upload_fs_after_upload`, or `park_servos_before_upload`. It links Adafruit's PWM library only. `include/pins.h` is on the include path for GPIO numbers and `PCA9685_ADDRESS`. + +Alternative: `-D PCBA_TEST` inside `src/main.cpp`. Rejected. The product boot would still be one edit away from running on a module that should boot the product, and the test image would still compile Wi-Fi and the UI scripts unless those scripts were also stripped. + +Alternative: a second repository. Rejected. Pin and channel numbers would drift from `pins.h`. + +### Plain lines, not the product serial protocol + +The image prints one token line at a time and reads one operator key. Banner `PCBA-TEST v1`. Steps `STEP tone`, then `STEP servos`, then `STEP oe`. Failures `FAIL `. Menus are the single letters below. Verdict `RESULT PASS` or `RESULT FAIL` plus the failed step names separated by spaces. Idle is `STOP` after `q`. A key that does not apply to the current state is ignored. Enter on the wire is a single line feed. + +Keys: Enter accepts, `n` rejects a step, `r` retries, `c` continues, `a` restarts the board, `q` stops after RESULT. After RESULT the next board is an unplug: USB power loss resets the module, and the host attaches when the port returns. `n` after RESULT is ignored. `y` is avoided because it moves on a Polish keyboard. + +Alternative: COBS frames shared with `src/serial/`. Rejected. The test host would need the product codec, and the product spec forbids raw text on the robot image. This image is not that image. + +### Step behavior + +PCA probe uses `Wire` at `0x40` before any step. Failure prints `FAIL pca` and `RESULT FAIL pca`, with no `r`/`c`/`a` menu. The board ends the same way as any other verdict: unplug for the next one, `q` to stop. + +Tone is a generated sine on the I2S pins (GP2, GP3, GP4), repeated until Enter or `n`. During that step `+` raises the level and `-` lowers it, across ten steps. The middle step is the bench default. Other steps ignore those keys. It does not call `playTone()` in `src/audio/audio.cpp`, which reads NVS volume. + +The servos step sweeps PWM duty on channels 0 through 4 together so every blue LED can pulse, with OE enabled (GP5 low). The operator plugs the testing board into one column at a time during that one step. The last step drives OE high so the pins turn off, while PWM keeps pulsing on channels 0 through 4. The 5 V rail stays on, so only the blue LED goes out. Restarting the board enables OE again. Silk-side pin is blue (SIG), middle pin is red (5 V), square pad is GND. Each column expects red on and blue pulsing. `tone` is the ear on J1; lamps are ignored. + +`r` repeats the current step and drops a fail recorded for that attempt. `c` appends the step name and advances. `a` clears the list and returns to the connected confirmation without a power cycle. Enter starts the tone again. On a step `FAIL` the host shows `r`, `c`, and `a` with the step name. `FAIL pca` does not. + +The onboard WS2812 (`RGB_LED_PIN`, GPIO10) is turned steady white once the image is up and left there through steps, the failure menu, `FAIL pca`, `RESULT`, and `STOP`. The three channels are equal, so `rgb_order` is not read and NVS is not opened. Red and green are not used. The lamp does not blink and does not encode pass or fail. Removing USB power is what turns it off. + +Alternative: blue, to dodge an R/G swap. Rejected. The product already allows `RBG`, `GBR`, `BRG`, and `BGR`, and those put blue on the red or green wire. White survives every order. + +### On-screen coaching + +The wire stays the token lines. Each host adds the same English sentences for the steps. A waiting step does not print the `STEP` token. It shows `Enter = good` and `n = bad` in the box footer, and its place in the three. The page shows the banner sentence. The script does not print it. The procedure card already says the lamp is not the verdict. + +| Token | On screen | +| --- | --- | +| banner | Page only. The module LED stays steady white while the test image has power. That lamp is not the board verdict. | +| `1/3` `tone` | Speaker on the JST speaker port. Expect a repeating tone. `+` louder, `-` quieter. The card shows the level. | +| `2/3` `servos` | Signal is on all five servo outputs. Take the testing board. Plug it into one column at a time. Columns are HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. Red stays on and blue pulses. | +| `3/3` OE OUTPUT ENABLE | The red LED stays on. Only the blue LED goes out. No need to test each servo column. | + +A step `FAIL` repeats that step's expected effect and shows `r = try this step again`, `c = keep the fail, go on`, and `a = start this board over`. `FAIL pca` shows `PCA9685 did not answer. This board fails before the speaker test.` and does not show `r`, `c`, or `a`. + +### Two hosts, one line protocol + +`scripts/pcba_test.py` uses Python 3 and `pyserial`. That install exists for Windows, macOS, and Linux. On start it prints `https://tinyengineer.dev/pcba_test` as the alternate tester. The script picks a single CDC port (or `--port`), prints the English coaching as the large line, shows `Enter = good` and `n = bad` in the box footer, shows `r`, `c`, and `a` when the line is a step `FAIL`, and writes keys to the port. On port loss it waits and opens the port that comes back. + +The alternate host is `web/pcba_test/index.html`, published at `https://tinyengineer.dev/pcba_test` the same way `web/flash/` is `/flash/`. A request without the trailing slash redirects to the slash form. The page opens the golden module with Web Serial, clears DTR and RTS, writes `?`, and speaks the same lines and keys. It is not a route in the robot `ui/`. The test image does not start HTTP. + +On load the page checks `isSecureContext` and `navigator.serial`, the same gate as `web/js/flash-status.js`. If either fails, the page says this browser cannot run the test, names `python3 scripts/pcba_test.py`, and shows no connect control. Chrome or Edge on the HTTPS site passes. The first open needs a click, because a serial grant comes only from a user gesture. The page then keeps that grant and reopens it when the cable moves, without a reload. After the port is open the page hides Connect and shows Disconnect. Disconnect closes the port and reloads the page. After the link drops, Connect comes back and the click asks for the port again. The page also names `python3 scripts/pcba_test.py` and links the procedure doc on GitHub. + +No HTML page under `web/` other than this one links to `/pcba_test`. The procedure card `docs/hardware/pcba-test.md` states the bench, the plug facing, that the servos step pulses all five columns while the operator moves the plug with no key between columns, the red/blue look, the steady white module LED, J1, the keys, unplug for the next board, that the golden module stays with the tester, `python3 scripts/pcba_test.py`, and `https://tinyengineer.dev/pcba_test`. + +Alternative: a `file://` HTML page. Rejected. Web Serial is blocked outside a secure context. Alternative: a route on the product panel or on the test image. Rejected. The test image does not start HTTP, and the product panel is the robot UI. Alternative: three native binaries. Deferred. The script covers every OS; the page covers Chromium on the site. + +### Golden module stays with the tester + +The test image is uploaded with `pio run -e pcba-test -t upload` onto the fixture module. That module stays with the person running the test. Both hosts say the ESP32 must already run the test firmware and point at the procedure section for how to get one. This change does not flash the product image onto a produced board. + +## Risks / Trade-offs + +- [Operator skips a column] → The servos step pulses all five outputs at once, and the card says to move the plug across every column before Enter. A missed column still logs as pass if the operator accepts. +- [Plug reversed 180°] → SIG and GND swap. Blue stays dark, so the step fails if the operator follows the card. The 1 kΩ on the red LED limits current into the PWM pin. +- [I2S init succeeds with a dead amplifier] → Pass/fail for `tone` is the operator's ear, not the init return code. +- [Windows COM number changes after replug] → The script treats disappearance as "wait" and attaches to the new CDC port instead of exiting. The page reopens the same granted device, because the golden module does not change. +- [Browser has no Web Serial] → The page names the Python command and does not offer a port connection. +- [Test image flashed onto a module that should run the product] → Default env is unchanged. The pcba-test upload command names `-e pcba-test`. The image banner is `PCBA-TEST`, not `TINY ENGINEER`. + +## Migration Plan + +No product NVS, HTTP, or serial change. Rollback is deleting the env and the example. A module that should run the product is reflashed with the product env before it leaves the test setup. + +## Open Questions + +None that change the session. The on-bench LED wiring drawing stays outside this change. diff --git a/openspec/changes/archive/2026-10-30-main-control-board-tester/proposal.md b/openspec/changes/archive/2026-10-30-main-control-board-tester/proposal.md new file mode 100644 index 00000000..f818ffb3 --- /dev/null +++ b/openspec/changes/archive/2026-10-30-main-control-board-tester/proposal.md @@ -0,0 +1,36 @@ +# Proposal + +## Why + +Anyone who wants to check a produced main control board needs a repeatable pass/fail. The product firmware boots Wi-Fi, centers servos, and treats I2S init as success, so it cannot run this check. A PCBA test image and a small host program should walk one person through the ESP32 socket, the speaker, and each servo column. + +## What Changes + +- Add an opt-in PlatformIO env `pcba-test` with its own `main`. The default robot env stays unchanged. The test image is flashed once onto a golden ESP32-C3-Zero that stays with the person running the test. +- The image talks plain USB CDC lines at 115200. It does not speak the product COBS serial protocol, start Wi-Fi, or mount LittleFS. While it has USB power the onboard LED stays steady white, including after `q`. That lamp only means the test image is running. +- One operator, one keyboard. Silk-side pin is blue, middle pin is red, square pad is GND. The tone step is the speaker. The servos step puts signal on all five servo outputs at once. The operator plugs the testing board into HEAD, NECK, ARM L, ARM R, and BODY, one column at a time. Enter accepts a step. `n` rejects it. +- On every rejected step the image asks: retry the step (`r`), record the failure and continue (`c`), or restart the whole board (`a`). The tone repeats until Enter or `n`. +- After `RESULT PASS` or `RESULT FAIL`, the host stays open. Unplugging USB starts the next board. `q` ends the session. `n` after the verdict does nothing. +- Add a Python 3 host (`pyserial`) that finds the CDC port, shows the current step or the verdict, forwards those keys, and reconnects when the USB cable moves to the next board. On start it prints `https://tinyengineer.dev/pcba_test` as the alternate tester. +- Add that web host at `https://tinyengineer.dev/pcba_test` as an alternate path to the script. It uses the same CDC lines. No other site page links to it. If the browser has no Web Serial, or the page is not a secure context, the page says so and points at the Python script. +- Both hosts, in English, say what the current step tests, what to do, and the expected effect, and still show the wire token. Steps are numbered `1/3` through `3/3`. `FAIL pca` does not show `r`, `c`, or `a`. +- Out of scope: J2, J3, J4, OLED, Wi-Fi, a 2 A load, using the test image as the robot's everyday firmware, and serving this page from the robot UI or from the test image. + +No **BREAKING** product HTTP, serial, or settings changes. The product binary is a different env. + +## Capabilities + +### New Capabilities + +- `pcba-test`: PCBA test session on the golden module and the host: boot checks, tone, all servo columns at once, failure menu, board verdict, next board or stop. + +### Modified Capabilities + +- (none — the product `serial-protocol` stays on the robot image; the PCBA test image uses a separate line protocol) + +## Impact + +- **Firmware**: new env in `platformio.ini` (same pattern as `expression-demo`); new `examples/pcba-test/main.cpp`. Pin numbers come from `include/pins.h`. Product `src/main.cpp` is not linked and not edited for a runtime test mode. +- **Host**: one Python script under `scripts/`, dependency `pyserial`. Launch is `python3` plus that script on Windows, macOS, or Linux. The script prints `https://tinyengineer.dev/pcba_test` as the alternate. That page is `web/pcba_test/` on tinyengineer.dev (same shape as `/flash/`). Not a route in the robot `ui/`. Other pages under `web/` do not link to it. Both hosts print the same English step coaching next to the wire token. +- **Test hardware** (not built in this change): 3-pin female plug with a red LED on 5 V and a blue LED on PWM, plus one test speaker on J1. +- **Docs**: `docs/hardware/pcba-test.md`, the procedure card for the person running the test. It names the bench, the plug facing, the one servos step that pulses every column while the operator moves the plug with no key between columns, the lamp pattern, the steady white module LED, J1, the keys, unplug for the next board, the golden module staying with the tester, the Python command, and `https://tinyengineer.dev/pcba_test`. Product API docs stay as they are. diff --git a/openspec/changes/archive/2026-10-30-main-control-board-tester/specs/pcba-test/spec.md b/openspec/changes/archive/2026-10-30-main-control-board-tester/specs/pcba-test/spec.md new file mode 100644 index 00000000..d0b10a8c --- /dev/null +++ b/openspec/changes/archive/2026-10-30-main-control-board-tester/specs/pcba-test/spec.md @@ -0,0 +1,326 @@ +# Spec Delta + +## Purpose + +Defines the PCBA test session: a golden-module image and a host, either the Python script or the web page, that walk one person through the ESP32 socket, the speaker, and the servo columns together, then record a pass or fail. + +## ADDED Requirements + +### Requirement: PCBA test image is not the product boot +The PCBA test image MUST start the PCBA session on USB connect. It MUST NOT join Wi-Fi, start HTTP, mount the audio filesystem, or speak the product COBS serial protocol. + +#### Scenario: Power-up banner +- **WHEN** the golden module receives USB power through a board under test +- **THEN** it prints PCBA-TEST v1 on USB CDC at 115200 +- **AND** it does not open the product setup AP or HTTP server + +### Requirement: PCA probe gates the session +Before the tone or any servo step, the image MUST probe I2C address 0x40. If nothing acknowledges, it MUST print a PCA failure and a final FAIL result and MUST NOT start the tone or servo steps. + +#### Scenario: PCA missing +- **WHEN** the session starts and address 0x40 does not acknowledge +- **THEN** the image prints FAIL pca and RESULT FAIL pca +- **AND** it does not play a tone or offer retry, continue, or restart + +#### Scenario: PCA present +- **WHEN** address 0x40 acknowledges +- **THEN** the image prints READY +- **AND** the tone has not started until the operator sends Enter + +### Requirement: Fixed step order +A board session MUST run three steps in this order: tone, then servos, then oe. The oe step MUST disable the PCA9685 outputs and MUST keep pulsing PWM on channels 0, 1, 2, 3, and 4. The servos step MUST pulse every servo column at the same time. + +#### Scenario: Happy path order +- **WHEN** the operator accepts every step +- **THEN** the image announces tone, then servos, then oe +- **AND** then prints a RESULT line + +### Requirement: Operator accepts or rejects the current step +Each step MUST hold its outputs until the operator sends Enter or `n`. Enter on the wire MUST be a single line feed and MUST record a pass for that step. `n` MUST record a fail for that step and present the failure menu. Any other key while the step is waiting for Enter or `n` MUST be ignored, except `+` and `-` on the tone step. + +#### Scenario: Accept tone +- **WHEN** the tone step is active and the operator sends Enter +- **THEN** the tone step is recorded as passed +- **AND** the session moves to servos + +#### Scenario: Reject a column +- **WHEN** a servo step is active and the operator sends `n` +- **THEN** that step is recorded as failed +- **AND** the image presents the failure menu before leaving the step + +### Requirement: Failure menu offers retry, continue, or restart +On every failed step the image MUST wait for `r`, `c`, or `a`. Any other key during that wait MUST be ignored. `r` MUST repeat the same step. `c` MUST keep the failure and advance. `a` MUST discard the board's results and return to the connected confirmation without removing USB power. The tone MUST NOT start until Enter. + +#### Scenario: Retry the same step +- **WHEN** the operator sends `r` after failing servos +- **THEN** the image announces servos again +- **AND** the previous fail for servos is not kept + +#### Scenario: Continue after a failure +- **WHEN** the operator sends `c` after failing a step +- **THEN** the session advances to the next step +- **AND** the failed step remains on the board's fail list + +#### Scenario: Restart the board +- **WHEN** the operator sends `a` during a board session +- **THEN** the fail list is cleared +- **AND** the image prints READY +- **AND** the tone has not started until the operator sends Enter + +### Requirement: All servo columns pulse together +During the servos step the image MUST pulse PWM duty on channels 0, 1, 2, 3, and 4 at the same time, with outputs enabled. The mapping MUST be head=0, neck=1, arm-l=2, arm-r=3, body=4. Moving the plug from column to column MUST NOT require a key. + +#### Scenario: Every column pulses +- **WHEN** the servos step is active +- **THEN** channels 0 through 4 are pulsing +- **AND** the outputs are enabled + +### Requirement: Tone is generated on the board +The tone step MUST play an audible tone through the I2S pins to the amplifier and MUST keep playing it until the operator sends Enter or `n`. The tone MUST NOT depend on files in the audio filesystem. + +#### Scenario: Tone uses I2S pins +- **WHEN** the tone step becomes active +- **THEN** the image emits a tone on the I2S clock, word-select, and data pins +- **AND** the tone is still emitting while the operator has not sent Enter or `n` + +### Requirement: Speaker step changes loudness +During the tone step `+` MUST make the tone louder and `-` MUST make it quieter without stopping the tone. At either end of the range that key MUST leave the level unchanged. Other steps MUST ignore `+` and `-`. The speaker card MUST show `+ = louder` and `- = quieter`. + +#### Scenario: Louder on the speaker step +- **WHEN** the tone step is active and the operator sends `+` +- **THEN** the tone keeps playing at a higher level +- **AND** the host shows + = louder + +#### Scenario: Quieter on the speaker step +- **WHEN** the tone step is active and the operator sends `-` +- **THEN** the tone keeps playing at a lower level + +#### Scenario: Other steps ignore volume keys +- **WHEN** the servos step is active and the operator sends `+` +- **THEN** the servo pulse continues unchanged + +### Requirement: One verdict line per board +When the step list finishes, the image MUST print a single RESULT line. RESULT PASS MUST be used only when every completed step was accepted. Otherwise the line MUST be RESULT FAIL followed by the failed step names separated by spaces, in step order. + +#### Scenario: All steps accepted +- **WHEN** the operator has accepted tone, servos, and oe +- **THEN** the image prints RESULT PASS + +#### Scenario: Continue past two failures +- **WHEN** the operator continued past failed tone and failed servos +- **THEN** the image prints RESULT FAIL tone servos + +### Requirement: Next board or stop after the verdict +After RESULT, removing USB power MUST end the session, and the next USB connect MUST start a new session at the banner. `q` MUST print STOP and MUST NOT start another step until power is removed and restored. `n` after RESULT MUST be ignored. + +#### Scenario: Cable leaves after the verdict +- **WHEN** the module loses USB power after RESULT +- **THEN** a later USB connect starts a new session at the banner + +#### Scenario: Operator stops +- **WHEN** the operator sends `q` after RESULT +- **THEN** the image prints STOP +- **AND** it does not announce another step until power is removed and restored + +#### Scenario: Reject key after the verdict +- **WHEN** the operator sends `n` after RESULT +- **THEN** the image does not start another step +- **AND** it does not treat that key as a board failure + +### Requirement: Host shows the step and survives the cable move +Each host MUST open the CDC port, show the current step or the RESULT line, and send Enter, `n`, `r`, `c`, `a`, and `q`. A step FAIL MUST show `r`, `c`, and `a`. FAIL pca MUST NOT. When the port returns, the host MUST attach without a relaunch. + +#### Scenario: Key forwards to the module +- **WHEN** the operator presses Enter while a step is on screen +- **THEN** the host sends a line feed to the module + +#### Scenario: Failure menu is on screen +- **WHEN** the module prints FAIL servos +- **THEN** the host shows `r`, `c`, and `a` + +#### Scenario: PCA failure hides the step menu +- **WHEN** the module prints FAIL pca +- **THEN** the host does not show `r`, `c`, or `a` + +#### Scenario: Cable moves to the next board +- **WHEN** the serial port drops and a CDC port returns +- **THEN** the host shows the new session's banner or step +- **AND** the operator does not start the program again + +### Requirement: Web tester lives at /pcba_test and checks the browser +https://tinyengineer.dev MUST serve the web host at `/pcba_test`. No other page on that site MUST link to it. When Web Serial is unavailable or the page is not a secure context, the page MUST say this browser cannot run the test and MUST name the Python host command, and it MUST NOT offer a port connection. When Web Serial is available in a secure context, the page MUST offer a connection and then run the same session as the script host. + +#### Scenario: Incompatible browser +- **WHEN** the page loads and Web Serial is missing or the context is not secure +- **THEN** the page states that this browser cannot run the test +- **AND** it names the Python host command +- **AND** it does not offer a port connection + +#### Scenario: Compatible browser +- **WHEN** the page loads in a secure context with Web Serial +- **THEN** the page offers a port connection +- **AND** after the port is open it shows steps and forwards the operator keys + +#### Scenario: No link from another site page +- **WHEN** a reader opens any other HTML page on the project site +- **THEN** that page does not link to `/pcba_test` + +### Requirement: Procedure card and script name the web tester +The procedure card MUST describe the bench, the step order, the expected lamps, the keys, and both ways to run the session. The card MUST say the golden module stays with the tester. The card and the script host MUST name the web tester as https://tinyengineer.dev/pcba_test. The script MUST show that address as the alternate to itself. + +#### Scenario: Card names the public page +- **WHEN** the operator reads the procedure card +- **THEN** it includes https://tinyengineer.dev/pcba_test +- **AND** it includes the Python host command +- **AND** it lists the step order and the keys + +#### Scenario: Script offers the web tester +- **WHEN** the script starts +- **THEN** it shows https://tinyengineer.dev/pcba_test as the alternate tester + +#### Scenario: Card keeps the golden module +- **WHEN** the operator reads the bench setup +- **THEN** the card says the golden module stays with the tester + +### Requirement: Plug position and lamp pattern +The procedure card MUST say signal is on all five servo outputs and the operator plugs the testing board into one column at a time: HEAD, NECK, ARM L, ARM R, and BODY. The card MUST name the silk-side pin as blue, the middle pin as red, and the square pad as GND. Each column MUST show red on and blue pulsing. Tone MUST be judged by ear on J1. + +#### Scenario: Servo step is one plug sweep +- **WHEN** the operator reads the servos step on the card +- **THEN** the card says signal is on all five servo outputs +- **AND** it says to plug the testing board into one column at a time +- **AND** the columns are HEAD, NECK, ARM L, ARM R, and BODY +- **AND** the expected look is red stays on and blue pulses + +#### Scenario: Plug faces the square pad +- **WHEN** the operator reads how to seat the plug +- **THEN** the card names the square pad as GND +- **AND** it names the silk-side pin as the blue LED + +### Requirement: Module LED shows the test image is running +While the test image has USB power it MUST hold the onboard LED steady white, including during a step, the failure menu, a PCA failure, RESULT, and STOP. The three channels MUST be equal. The LED MUST NOT blink. The procedure card MUST say this steady white means the test image is running, and that board pass or fail is the ear on J1 and the plug lamps. + +#### Scenario: Session stays white +- **WHEN** the image is in a step, the failure menu, RESULT, or STOP +- **THEN** the onboard LED is steady white + +#### Scenario: PCA failure stays white +- **WHEN** address 0x40 does not acknowledge +- **THEN** the onboard LED is steady white +- **AND** the image still prints RESULT FAIL pca + +#### Scenario: Card names the module lamp +- **WHEN** the operator reads the bench setup +- **THEN** the card says the module LED stays steady white while the test image has power + +### Requirement: Host explains the current step in English +Each host MUST show English text for the current step: what is tested, what to do, and the expected effect. A waiting step MUST NOT show the STEP token. Steps MUST be numbered 1/3 through 3/3. A waiting step MUST show Enter as good and n as bad. A step FAIL MUST show that step's expected effect and words for r, c, and a. FAIL pca MUST NOT show r, c, or a. Both hosts MUST use the same step sentences. + +#### Scenario: Tone step explains the ear +- **WHEN** the module prints STEP tone +- **THEN** the host shows 1/3 +- **AND** it shows Speaker on the JST speaker port. Expect a repeating tone. +- **AND** it does not show the token STEP tone +- **AND** it shows Enter = good and n = bad + +#### Scenario: Servo step is one sweep +- **WHEN** the module prints STEP servos +- **THEN** the host shows 2/3 +- **AND** it shows Signal is on all five servo outputs. Take the testing board. Plug it into one column at a time. Columns are HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. Red stays on and blue pulses. +- **AND** it does not show the token STEP servos + +#### Scenario: OE step releases the outputs +- **WHEN** the module prints STEP oe +- **THEN** the host shows 3/3 OE OUTPUT ENABLE +- **AND** it shows The red LED stays on. Only the blue LED goes out. +- **AND** it shows No need to test each servo column. +- **AND** it does not show the token STEP oe + +#### Scenario: Step failure names the keys +- **WHEN** the module prints FAIL servos +- **THEN** the host shows Red stays on and blue pulses. +- **AND** it shows r = try this step again +- **AND** it shows c = keep the fail, go on +- **AND** it shows a = start this board over + +#### Scenario: PCA failure explains the stop +- **WHEN** the module prints FAIL pca +- **THEN** the host shows PCA9685 did not answer. This board fails before the speaker test. +- **AND** it does not show r, c, or a + +### Requirement: Banner lamp sentence is page only +When the banner arrives, the page MUST show that the module LED stays steady white and is not the board verdict. The script MUST NOT show that sentence. + +#### Scenario: Page names the module lamp +- **WHEN** the page reads PCBA-TEST v1 +- **THEN** it shows The module LED stays steady white while the test image has power. That lamp is not the board verdict. + +#### Scenario: Script hides the banner sentence +- **WHEN** the script reads PCBA-TEST v1 +- **THEN** it does not show that lamp sentence + +### Requirement: Hosts name the board revision +The script, the page, and the procedure card MUST say the test is compatible with main control board rev 3. + +#### Scenario: Script names the revision +- **WHEN** the script starts +- **THEN** it shows Compatible with main control board rev 3. + +#### Scenario: Page names the revision +- **WHEN** the page loads +- **THEN** it shows Compatible with main control board rev 3. + +#### Scenario: Card names the revision +- **WHEN** the operator reads the procedure card +- **THEN** the card says the test is compatible with main control board rev 3 + +### Requirement: Web page controls the open port +After the port opens, the page MUST hide Connect and show Disconnect. Disconnect MUST close the port and reload the page. The page MUST keep the serial grant and reopen it when the cable returns, without a reload. After the link drops, Connect MUST return and that click MUST ask for the port again. + +#### Scenario: Port is open +- **WHEN** the operator opens the port +- **THEN** Connect is hidden +- **AND** Disconnect is shown + +#### Scenario: Operator disconnects +- **WHEN** the operator presses Disconnect +- **THEN** the page closes the port and reloads + +#### Scenario: Link drops +- **WHEN** the open port is lost +- **THEN** Connect returns +- **AND** that click asks for the port again + +### Requirement: Page names the script and the procedure +The page MUST name `python3 scripts/pcba_test.py` and MUST link the procedure at `https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md`. + +#### Scenario: Script path on the page +- **WHEN** the page loads in a browser that can run the test +- **THEN** the page names python3 scripts/pcba_test.py +- **AND** it links the procedure doc on GitHub + +### Requirement: Script waits on a busy port +When the script cannot open the board port because it is busy, it MUST say the port is busy and MUST keep waiting. It MUST NOT exit with a traceback. + +#### Scenario: Another program holds the port +- **WHEN** the board port is busy +- **THEN** the script shows Port is busy. Close the other program using the board. This script will keep waiting. +- **AND** the script stays running + +### Requirement: Hosts require the test firmware +Both hosts MUST say the ESP32 must already run the test firmware. The script MUST print, and the page MUST link, the procedure section on how to get one. The procedure MUST say the product firmware cannot run this test and MUST include the pcba-test upload command. + +#### Scenario: Script names the firmware +- **WHEN** the script starts +- **THEN** it shows The ESP32 must already run the test firmware. +- **AND** it shows https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md#get-an-esp32-with-the-test-firmware + +#### Scenario: Page names the firmware +- **WHEN** the page loads +- **THEN** it shows The ESP32 must already run the test firmware. +- **AND** it links https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md#get-an-esp32-with-the-test-firmware + +#### Scenario: Card explains how to get one +- **WHEN** the operator reads how to get the test firmware +- **THEN** the card says the product firmware cannot run this test +- **AND** it includes pio run -e pcba-test -t upload diff --git a/openspec/changes/archive/2026-10-30-main-control-board-tester/tasks.md b/openspec/changes/archive/2026-10-30-main-control-board-tester/tasks.md new file mode 100644 index 00000000..7227a932 --- /dev/null +++ b/openspec/changes/archive/2026-10-30-main-control-board-tester/tasks.md @@ -0,0 +1,25 @@ +# Tasks + +## 1. PCBA test image + +- [x] 1.1 Add `[env:pcba-test]` and `examples/pcba-test/main.cpp` that prints `PCBA-TEST v1` on USB CDC and does not attach product `extra_scripts`. Verify `pio run -e pcba-test` exits 0 and `default_envs` in `platformio.ini` is still `esp32-c3-devkitm-1`. +- [x] 1.2 Implement the session in that `main`: PCA probe at `0x40`, steps `tone`, `servos`, and `oe`, keys Enter/`n`/`r`/`c`/`a`/`q`, repeating tone until Enter or `n`, OE high during `oe` while PWM keeps pulsing on all five channels, stays disabled after Enter or `c` finish the board, and `a` enables it again through restart, `n` after `RESULT` ignored, and lines `PCBA-TEST v1`, `STEP`, `FAIL`, `RESULT PASS`, `RESULT FAIL` with space-separated names, and `STOP`. Verify `pio run -e pcba-test` exits 0 and the example source names `tone`, `servos`, and `oe` in that order. +- [x] 1.3 Hold the onboard LED on GPIO10 steady white with equal channels from boot through STOP, including a PCA failure. Do not blink it and do not read `rgb_order`. Verify `pio run -e pcba-test` exits 0 and the example source writes equal channel values to that pin. + +## 2. Host and operator card + +- [x] 2.1 Add `scripts/pcba_test.py` that reads `STEP`, `FAIL`, `RESULT`, and `STOP` lines, sends Enter as a line feed plus `n`, `r`, `c`, `a`, and `q`, shows `r`, `c`, and `a` when the line is `FAIL`, and on start prints `https://tinyengineer.dev/pcba_test` as the alternate tester. Verify a unit test feeds a scripted accept path and a scripted `n` then `c` path, checks the shown step and the `r`/`c`/`a` prompt, and checks that startup text contains that URL. +- [x] 2.2 On port loss, wait and open the returning CDC port. Verify a unit test drops the fake port, reconnects, and checks the next session banner. +- [x] 2.3 Write `docs/hardware/pcba-test.md` as the procedure card: bench setup, the testing board one column at a time, lamp pattern, J1, keys, unplug for the next board, golden module stays with the tester, `python3 scripts/pcba_test.py`, and `https://tinyengineer.dev/pcba_test`. Verify the doc lists `tone`, `servos`, `oe`, HEAD, NECK, ARM L, ARM R, BODY, keys `r`, `c`, `a`, `n`, `q`, `python3 scripts/pcba_test.py`, `https://tinyengineer.dev/pcba_test`, red stays on and blue pulses, square pad as GND, J1, and that the golden module stays with the tester. +- [x] 2.4 Add `web/pcba_test/index.html` that, when `navigator.serial` is missing or the context is not secure, says this browser cannot run the test, names `python3 scripts/pcba_test.py`, and shows no connect control. Verify a unit test of that gate for the failing cases and the Chrome-on-HTTPS case, and that no other HTML file under `web/` links to `pcba_test`. +- [x] 2.5 On a passing browser, open the golden module with Web Serial, show the current step, forward Enter, `n`, `r`, `c`, `a`, and `q`, and reopen the granted port when it returns without reloading the page. Verify a unit test feeds a scripted `STEP` then `RESULT` and a disconnect-then-connect, and checks the shown step and that the page did not ask for a new grant. +- [x] 2.6 Update `docs/hardware/pcba-test.md` so the bench setup says the module LED stays steady white while the test image has power, and that this lamp is not the board verdict. Verify the doc contains `steady white`, red stays on and blue pulses, and only the blue LED goes out. + +## 3. Session dry run + +- [x] 3.1 Point the host at a fake device that prints the banner and walks an all-accept session, then a session that fails `tone` and `servos` with `c`. Verify the host log shows `RESULT PASS` and `RESULT FAIL tone servos`, and the operator card matches that dialogue. + +## 4. On-screen coaching + +- [x] 4.1 In both hosts, show English coaching for every `STEP`: the index `1/3` through `3/3`, what is tested, what to do, the expected effect, `Enter = good`, `n = bad`, and the wire token. The script and the page use the same three sentences. Verify unit tests for `STEP tone` (`1/3`, speaker, repeating tone), `STEP servos` (`2/3`, testing board one column at a time, red stays on and blue pulses), and `STEP oe` (`3/3`, only the blue LED goes out). +- [x] 4.2 On a step `FAIL`, show that step's expected effect and `r = try this step again`, `c = keep the fail, go on`, `a = start this board over`. On `FAIL pca`, show that the PCA9685 did not answer and do not show `r`, `c`, or `a`. On the banner, say the module LED stays steady white and is not the board verdict. Verify unit tests for `FAIL servos`, `FAIL pca`, and `PCBA-TEST v1`. diff --git a/openspec/specs/pcba-test/spec.md b/openspec/specs/pcba-test/spec.md new file mode 100644 index 00000000..c3942b83 --- /dev/null +++ b/openspec/specs/pcba-test/spec.md @@ -0,0 +1,326 @@ +# pcba-test Specification + +## Purpose + +Defines the PCBA test session: a golden-module image and a host, either the Python script or the web page, that walk one person through the ESP32 socket, the speaker, and the servo columns together, then record a pass or fail. + +## Requirements + +### Requirement: PCBA test image is not the product boot +The PCBA test image MUST start the PCBA session on USB connect. It MUST NOT join Wi-Fi, start HTTP, mount the audio filesystem, or speak the product COBS serial protocol. + +#### Scenario: Power-up banner +- **WHEN** the golden module receives USB power through a board under test +- **THEN** it prints PCBA-TEST v1 on USB CDC at 115200 +- **AND** it does not open the product setup AP or HTTP server + +### Requirement: PCA probe gates the session +Before the tone or any servo step, the image MUST probe I2C address 0x40. If nothing acknowledges, it MUST print a PCA failure and a final FAIL result and MUST NOT start the tone or servo steps. + +#### Scenario: PCA missing +- **WHEN** the session starts and address 0x40 does not acknowledge +- **THEN** the image prints FAIL pca and RESULT FAIL pca +- **AND** it does not play a tone or offer retry, continue, or restart + +#### Scenario: PCA present +- **WHEN** address 0x40 acknowledges +- **THEN** the image prints READY +- **AND** the tone has not started until the operator sends Enter + +### Requirement: Fixed step order +A board session MUST run three steps in this order: tone, then servos, then oe. The oe step MUST disable the PCA9685 outputs and MUST keep pulsing PWM on channels 0, 1, 2, 3, and 4. The servos step MUST pulse every servo column at the same time. + +#### Scenario: Happy path order +- **WHEN** the operator accepts every step +- **THEN** the image announces tone, then servos, then oe +- **AND** then prints a RESULT line + +### Requirement: Operator accepts or rejects the current step +Each step MUST hold its outputs until the operator sends Enter or `n`. Enter on the wire MUST be a single line feed and MUST record a pass for that step. `n` MUST record a fail for that step and present the failure menu. Any other key while the step is waiting for Enter or `n` MUST be ignored, except `+` and `-` on the tone step. + +#### Scenario: Accept tone +- **WHEN** the tone step is active and the operator sends Enter +- **THEN** the tone step is recorded as passed +- **AND** the session moves to servos + +#### Scenario: Reject a column +- **WHEN** a servo step is active and the operator sends `n` +- **THEN** that step is recorded as failed +- **AND** the image presents the failure menu before leaving the step + +### Requirement: Failure menu offers retry, continue, or restart +On every failed step the image MUST wait for `r`, `c`, or `a`. Any other key during that wait MUST be ignored. `r` MUST repeat the same step. `c` MUST keep the failure and advance. `a` MUST discard the board's results and return to the connected confirmation without removing USB power. The tone MUST NOT start until Enter. + +#### Scenario: Retry the same step +- **WHEN** the operator sends `r` after failing servos +- **THEN** the image announces servos again +- **AND** the previous fail for servos is not kept + +#### Scenario: Continue after a failure +- **WHEN** the operator sends `c` after failing a step +- **THEN** the session advances to the next step +- **AND** the failed step remains on the board's fail list + +#### Scenario: Restart the board +- **WHEN** the operator sends `a` during a board session +- **THEN** the fail list is cleared +- **AND** the image prints READY +- **AND** the tone has not started until the operator sends Enter + +### Requirement: All servo columns pulse together +During the servos step the image MUST pulse PWM duty on channels 0, 1, 2, 3, and 4 at the same time, with outputs enabled. The mapping MUST be head=0, neck=1, arm-l=2, arm-r=3, body=4. Moving the plug from column to column MUST NOT require a key. + +#### Scenario: Every column pulses +- **WHEN** the servos step is active +- **THEN** channels 0 through 4 are pulsing +- **AND** the outputs are enabled + +### Requirement: Tone is generated on the board +The tone step MUST play an audible tone through the I2S pins to the amplifier and MUST keep playing it until the operator sends Enter or `n`. The tone MUST NOT depend on files in the audio filesystem. + +#### Scenario: Tone uses I2S pins +- **WHEN** the tone step becomes active +- **THEN** the image emits a tone on the I2S clock, word-select, and data pins +- **AND** the tone is still emitting while the operator has not sent Enter or `n` + +### Requirement: Speaker step changes loudness +During the tone step `+` MUST make the tone louder and `-` MUST make it quieter without stopping the tone. At either end of the range that key MUST leave the level unchanged. Other steps MUST ignore `+` and `-`. The speaker card MUST show `+ = louder` and `- = quieter`. + +#### Scenario: Louder on the speaker step +- **WHEN** the tone step is active and the operator sends `+` +- **THEN** the tone keeps playing at a higher level +- **AND** the host shows + = louder + +#### Scenario: Quieter on the speaker step +- **WHEN** the tone step is active and the operator sends `-` +- **THEN** the tone keeps playing at a lower level + +#### Scenario: Other steps ignore volume keys +- **WHEN** the servos step is active and the operator sends `+` +- **THEN** the servo pulse continues unchanged + +### Requirement: One verdict line per board +When the step list finishes, the image MUST print a single RESULT line. RESULT PASS MUST be used only when every completed step was accepted. Otherwise the line MUST be RESULT FAIL followed by the failed step names separated by spaces, in step order. + +#### Scenario: All steps accepted +- **WHEN** the operator has accepted tone, servos, and oe +- **THEN** the image prints RESULT PASS + +#### Scenario: Continue past two failures +- **WHEN** the operator continued past failed tone and failed servos +- **THEN** the image prints RESULT FAIL tone servos + +### Requirement: Next board or stop after the verdict +After RESULT, removing USB power MUST end the session, and the next USB connect MUST start a new session at the banner. `q` MUST print STOP and MUST NOT start another step until power is removed and restored. `n` after RESULT MUST be ignored. + +#### Scenario: Cable leaves after the verdict +- **WHEN** the module loses USB power after RESULT +- **THEN** a later USB connect starts a new session at the banner + +#### Scenario: Operator stops +- **WHEN** the operator sends `q` after RESULT +- **THEN** the image prints STOP +- **AND** it does not announce another step until power is removed and restored + +#### Scenario: Reject key after the verdict +- **WHEN** the operator sends `n` after RESULT +- **THEN** the image does not start another step +- **AND** it does not treat that key as a board failure + +### Requirement: Host shows the step and survives the cable move +Each host MUST open the CDC port, show the current step or the RESULT line, and send Enter, `n`, `r`, `c`, `a`, and `q`. A step FAIL MUST show `r`, `c`, and `a`. FAIL pca MUST NOT. When the port returns, the host MUST attach without a relaunch. + +#### Scenario: Key forwards to the module +- **WHEN** the operator presses Enter while a step is on screen +- **THEN** the host sends a line feed to the module + +#### Scenario: Failure menu is on screen +- **WHEN** the module prints FAIL servos +- **THEN** the host shows `r`, `c`, and `a` + +#### Scenario: PCA failure hides the step menu +- **WHEN** the module prints FAIL pca +- **THEN** the host does not show `r`, `c`, or `a` + +#### Scenario: Cable moves to the next board +- **WHEN** the serial port drops and a CDC port returns +- **THEN** the host shows the new session's banner or step +- **AND** the operator does not start the program again + +### Requirement: Web tester lives at /pcba_test and checks the browser +https://tinyengineer.dev MUST serve the web host at `/pcba_test`. No other page on that site MUST link to it. When Web Serial is unavailable or the page is not a secure context, the page MUST say this browser cannot run the test and MUST name the Python host command, and it MUST NOT offer a port connection. When Web Serial is available in a secure context, the page MUST offer a connection and then run the same session as the script host. + +#### Scenario: Incompatible browser +- **WHEN** the page loads and Web Serial is missing or the context is not secure +- **THEN** the page states that this browser cannot run the test +- **AND** it names the Python host command +- **AND** it does not offer a port connection + +#### Scenario: Compatible browser +- **WHEN** the page loads in a secure context with Web Serial +- **THEN** the page offers a port connection +- **AND** after the port is open it shows steps and forwards the operator keys + +#### Scenario: No link from another site page +- **WHEN** a reader opens any other HTML page on the project site +- **THEN** that page does not link to `/pcba_test` + +### Requirement: Procedure card and script name the web tester +The procedure card MUST describe the bench, the step order, the expected lamps, the keys, and both ways to run the session. The card MUST say the golden module stays with the tester. The card and the script host MUST name the web tester as https://tinyengineer.dev/pcba_test. The script MUST show that address as the alternate to itself. + +#### Scenario: Card names the public page +- **WHEN** the operator reads the procedure card +- **THEN** it includes https://tinyengineer.dev/pcba_test +- **AND** it includes the Python host command +- **AND** it lists the step order and the keys + +#### Scenario: Script offers the web tester +- **WHEN** the script starts +- **THEN** it shows https://tinyengineer.dev/pcba_test as the alternate tester + +#### Scenario: Card keeps the golden module +- **WHEN** the operator reads the bench setup +- **THEN** the card says the golden module stays with the tester + +### Requirement: Plug position and lamp pattern +The procedure card MUST say signal is on all five servo outputs and the operator plugs the testing board into one column at a time: HEAD, NECK, ARM L, ARM R, and BODY. The card MUST name the silk-side pin as yellow, the middle pin as red, and the square pad as GND. Each column MUST show red on and yellow pulsing. Tone MUST be judged by ear on J1. + +#### Scenario: Servo step is one plug sweep +- **WHEN** the operator reads the servos step on the card +- **THEN** the card says signal is on all five servo outputs +- **AND** it says to plug the testing board into one column at a time +- **AND** the columns are HEAD, NECK, ARM L, ARM R, and BODY +- **AND** the expected look is red stays on and yellow pulses + +#### Scenario: Plug faces the square pad +- **WHEN** the operator reads how to seat the plug +- **THEN** the card names the square pad as GND +- **AND** it names the silk-side pin as the yellow LED + +### Requirement: Module LED shows the test image is running +While the test image has USB power it MUST hold the onboard LED steady white, including during a step, the failure menu, a PCA failure, RESULT, and STOP. The three channels MUST be equal. The LED MUST NOT blink. The procedure card MUST say this steady white means the test image is running, and that board pass or fail is the ear on J1 and the plug lamps. + +#### Scenario: Session stays white +- **WHEN** the image is in a step, the failure menu, RESULT, or STOP +- **THEN** the onboard LED is steady white + +#### Scenario: PCA failure stays white +- **WHEN** address 0x40 does not acknowledge +- **THEN** the onboard LED is steady white +- **AND** the image still prints RESULT FAIL pca + +#### Scenario: Card names the module lamp +- **WHEN** the operator reads the bench setup +- **THEN** the card says the module LED stays steady white while the test image has power + +### Requirement: Host explains the current step in English +Each host MUST show English text for the current step: what is tested, what to do, and the expected effect. A waiting step MUST NOT show the STEP token. Steps MUST be numbered 1/3 through 3/3. A waiting step MUST show Enter as good and n as bad. A step FAIL MUST show that step's expected effect and words for r, c, and a. FAIL pca MUST NOT show r, c, or a. Both hosts MUST use the same step sentences. + +#### Scenario: Tone step explains the ear +- **WHEN** the module prints STEP tone +- **THEN** the host shows 1/3 +- **AND** it shows Speaker on the JST speaker port. Expect a repeating tone. +- **AND** it does not show the token STEP tone +- **AND** it shows Enter = good and n = bad + +#### Scenario: Servo step is one sweep +- **WHEN** the module prints STEP servos +- **THEN** the host shows 2/3 +- **AND** it shows Signal is on all five servo outputs. Take the testing board. Plug it into one column at a time. Columns are HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. Red stays on and yellow pulses. +- **AND** it does not show the token STEP servos + +#### Scenario: OE step releases the outputs +- **WHEN** the module prints STEP oe +- **THEN** the host shows 3/3 OE OUTPUT ENABLE +- **AND** it shows The red LED stays on. Only the yellow LED goes out. +- **AND** it shows No need to test each servo column. +- **AND** it does not show the token STEP oe + +#### Scenario: Step failure names the keys +- **WHEN** the module prints FAIL servos +- **THEN** the host shows Red stays on and yellow pulses. +- **AND** it shows r = try this step again +- **AND** it shows c = keep the fail, go on +- **AND** it shows a = start this board over + +#### Scenario: PCA failure explains the stop +- **WHEN** the module prints FAIL pca +- **THEN** the host shows PCA9685 did not answer. This board fails before the speaker test. +- **AND** it does not show r, c, or a + +### Requirement: Banner lamp sentence is page only +When the banner arrives, the page MUST show that the module LED stays steady white and is not the board verdict. The script MUST NOT show that sentence. + +#### Scenario: Page names the module lamp +- **WHEN** the page reads PCBA-TEST v1 +- **THEN** it shows The module LED stays steady white while the test image has power. That lamp is not the board verdict. + +#### Scenario: Script hides the banner sentence +- **WHEN** the script reads PCBA-TEST v1 +- **THEN** it does not show that lamp sentence + +### Requirement: Hosts name the board revision +The script, the page, and the procedure card MUST say the test is compatible with main control board rev 3. + +#### Scenario: Script names the revision +- **WHEN** the script starts +- **THEN** it shows Compatible with main control board rev 3. + +#### Scenario: Page names the revision +- **WHEN** the page loads +- **THEN** it shows Compatible with main control board rev 3. + +#### Scenario: Card names the revision +- **WHEN** the operator reads the procedure card +- **THEN** the card says the test is compatible with main control board rev 3 + +### Requirement: Web page controls the open port +After the port opens, the page MUST hide Connect and show Disconnect. Disconnect MUST close the port and reload the page. The page MUST keep the serial grant and reopen it when the cable returns, without a reload. After the link drops, Connect MUST return and that click MUST ask for the port again. + +#### Scenario: Port is open +- **WHEN** the operator opens the port +- **THEN** Connect is hidden +- **AND** Disconnect is shown + +#### Scenario: Operator disconnects +- **WHEN** the operator presses Disconnect +- **THEN** the page closes the port and reloads + +#### Scenario: Link drops +- **WHEN** the open port is lost +- **THEN** Connect returns +- **AND** that click asks for the port again + +### Requirement: Page names the script and the procedure +The page MUST name `python3 scripts/pcba_test.py` and MUST link the procedure at `https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md`. + +#### Scenario: Script path on the page +- **WHEN** the page loads in a browser that can run the test +- **THEN** the page names python3 scripts/pcba_test.py +- **AND** it links the procedure doc on GitHub + +### Requirement: Script waits on a busy port +When the script cannot open the board port because it is busy, it MUST say the port is busy and MUST keep waiting. It MUST NOT exit with a traceback. + +#### Scenario: Another program holds the port +- **WHEN** the board port is busy +- **THEN** the script shows Port is busy. Close the other program using the board. This script will keep waiting. +- **AND** the script stays running + +### Requirement: Hosts require the test firmware +Both hosts MUST say the ESP32 must already run the test firmware. The script MUST print, and the page MUST link, the procedure section on how to get one. The procedure MUST say the product firmware cannot run this test and MUST include the pcba-test upload command. + +#### Scenario: Script names the firmware +- **WHEN** the script starts +- **THEN** it shows The ESP32 must already run the test firmware. +- **AND** it shows https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md#get-an-esp32-with-the-test-firmware + +#### Scenario: Page names the firmware +- **WHEN** the page loads +- **THEN** it shows The ESP32 must already run the test firmware. +- **AND** it links https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/pcba-test.md#get-an-esp32-with-the-test-firmware + +#### Scenario: Card explains how to get one +- **WHEN** the operator reads how to get the test firmware +- **THEN** the card says the product firmware cannot run this test +- **AND** it includes pio run -e pcba-test -t upload diff --git a/platformio.ini b/platformio.ini index 58d83047..1a3d95d1 100644 --- a/platformio.ini +++ b/platformio.ini @@ -88,3 +88,17 @@ build_src_filter = -<*> +<../examples/expression-demo/main.cpp> test_ignore = * + +; Opt-in PCBA session. Building does not upload or change the default robot env. +[env:pcba-test] +platform = ${env:esp32-c3-devkitm-1.platform} +board = ${env:esp32-c3-devkitm-1.board} +framework = ${env:esp32-c3-devkitm-1.framework} +monitor_speed = ${env:esp32-c3-devkitm-1.monitor_speed} +build_flags = ${env:esp32-c3-devkitm-1.build_flags} +lib_deps = + adafruit/Adafruit PWM Servo Driver Library +build_src_filter = + -<*> + +<../examples/pcba-test/main.cpp> +test_ignore = * diff --git a/scripts/pcba_test.py b/scripts/pcba_test.py new file mode 100644 index 00000000..7f5d4ae4 --- /dev/null +++ b/scripts/pcba_test.py @@ -0,0 +1,440 @@ +#!/usr/bin/env python3 +"""PCBA host for the golden-module line protocol. Does not flash.""" + +import argparse +import os +import sys +import time + +WEB_TESTER = "https://tinyengineer.dev/pcba_test" +BOARD_REV = "Compatible with main control board rev 3." +FIRMWARE_LINE = "The ESP32 must already run the test firmware." +FIRMWARE_DOC = ( + "https://github.com/jamro/tiny-engineer/blob/main/docs/hardware/" + "pcba-test.md#get-an-esp32-with-the-test-firmware" +) +ESPRESSIF_VID = 0x303A + + +class PortLost(OSError): + pass + + +HEADER = """\ + .---. + | o o | TINY ENGINEER + | ^ | PCBA test + '---' +""" + + +def startup_text(): + return "%sWeb tester: %s\n%s\n%s\nHow to get one: %s\n" % ( + HEADER, + WEB_TESTER, + BOARD_REV, + FIRMWARE_LINE, + FIRMWARE_DOC, + ) + + +def prep_text(): + return card( + [ + "PREPARE", + "", + "1 Take the board.", + "2 Plug in the ESP32.", + " Match the USB mark on the board.", + "3 Plug the speaker into the JST speaker port.", + "4 Connect USB to the board.", + " Use the board socket, not the ESP32.", + ] + ) + + +READY_COACH = "The board is connected." +BANNER_COACH = ( + "The module LED stays steady white while the test image has power. " + "That lamp is not the board verdict." +) +PCA_COACH = "PCA9685 did not answer. This board fails before the speaker test." +WAIT_KEYS = ("Enter = good", "n = bad") +TONE_KEYS = ("+ = louder", "- = quieter") +TONE_LEVELS = 10 +TONE_LEVEL_DEFAULT = 6 +FAIL_KEYS = ( + "r = try this step again", + "c = keep the fail, go on", + "a = start this board over", +) +STEPS = ( + ("tone", "SPEAKER", "Speaker on the JST speaker port. Expect a repeating tone."), + ( + "servos", + "SERVOS", + "Signal is on all five servo outputs. Take the testing board. Plug it into one column at a time. Columns are HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. Red stays on and yellow pulses.", + ), + ( + "oe", + "OE OUTPUT ENABLE", + "The red LED stays on. Only the yellow LED goes out. No need to test each servo column.", + ), +) +STEP_TEXT = {name: sentence for name, _title, sentence in STEPS} +STEP_TITLE = {name: title for name, title, _sentence in STEPS} + + +def new_state(): + return {"shown": "", "menu": False, "volume": TONE_LEVEL_DEFAULT, "step": ""} + + +def card(lines, footer=None): + body = list(lines) + foot = list(footer or []) + width = max(len(line) for line in body + foot) + rule = "─" * (width + 2) + framed = ["┌" + rule + "┐"] + for line in body: + framed.append("│ " + line.ljust(width) + " │") + if foot: + framed.append("├" + rule + "┤") + for line in foot: + framed.append("│ " + line.ljust(width) + " │") + framed.append("└" + rule + "┘") + return "\n".join(framed) + + +def prose(text): + return [part if part.endswith(".") else part + "." for part in text.split(". ") if part] + + +def coach_step(name, volume=None): + index = next(i for i, (step, _title, _sentence) in enumerate(STEPS) if step == name) + lines = ["%d/%d %s" % (index + 1, len(STEPS), STEP_TITLE[name]), ""] + lines.extend(prose(STEP_TEXT[name])) + footer = WAIT_KEYS + if name == "tone": + level = TONE_LEVEL_DEFAULT if volume is None else volume + lines.append("Volume %d/%d." % (level, TONE_LEVELS)) + footer = TONE_KEYS + WAIT_KEYS + return card(lines, footer=footer) + + +def coach_fail(name, token): + if name == "pca": + return card(["PCA", ""] + prose(PCA_COACH) + ["", token]) + if name not in STEP_TEXT: + return token + lines = [STEP_TITLE[name], ""] + lines.extend(prose(STEP_TEXT[name])) + lines.append("") + lines.extend(FAIL_KEYS) + lines.extend(["", token]) + return card(lines) + + +def coach_ready(): + return card(["CONNECTED", ""] + prose(READY_COACH), footer=("Enter = continue",)) + + +def feed_line(state, line): + text = line.strip() + if not text: + return False + if text.startswith("STEP "): + name = text[5:] + state["step"] = name + state["shown"] = coach_step(name, state.get("volume")) if name in STEP_TEXT else text + state["menu"] = False + elif text.startswith("VOL "): + try: + level = int(text[4:]) + except ValueError: + return False + if level < 1 or level > TONE_LEVELS: + return False + state["volume"] = level + if state.get("step") == "tone": + state["shown"] = coach_step("tone", level) + state["menu"] = False + elif text.startswith("FAIL "): + name = text[5:] + state["shown"] = coach_fail(name, text) + state["menu"] = name in STEP_TEXT + elif text.startswith("RESULT "): + state["shown"] = card(["BOARD", "", text, "", next_action_text().strip()]) + state["menu"] = False + elif text == "READY": + state["shown"] = coach_ready() + state["menu"] = False + elif text.startswith("PCBA-TEST"): + state["shown"] = "%s\n%s" % (BANNER_COACH, text) + state["menu"] = False + elif text == "STOP": + state["shown"] = text + state["menu"] = False + else: + return False + state["echo"] = not text.startswith("PCBA-TEST") + return True + + +def display(state): + return state["shown"] + + +KEY_CHARS = frozenset("nrcaq+-=") + + +def token_for_char(ch): + if ch in ("\n", "\r"): + return "enter" + if ch in KEY_CHARS: + return ch + return None + + +def windows_key(ch, read_extended): + if ch in ("\x00", "\xe0"): + read_extended() + return None + return token_for_char(ch) + + +def encode_key(key): + if key == "enter": + return b"\n" + if key in ("+", "="): + return b"+" + if key in ("n", "r", "c", "a", "q", "-"): + return key.encode("ascii") + raise ValueError(key) + + +def next_action_text(): + return "unplug USB for the next board, or q to stop\n" + + +def read_chunk(port): + """Bytes already buffered, or one fake-port line. Does not block the keyboard. + + macOS CDC often leaves in_waiting at 0 until read() polls the kernel, so a + select-then-in_waiting loop never sees the banner. + """ + if not hasattr(port, "fileno"): + return port.readline() + try: + waiting = getattr(port, "in_waiting", 0) or 0 + if waiting: + return port.read(waiting) + timeout = port.timeout + port.timeout = 0.05 + try: + return port.read(4096) or b"" + finally: + port.timeout = timeout + except OSError as exc: + # macOS pyserial raises when a CDC read is signaled but returns nothing. + if "no data" in str(exc).lower(): + return b"" + raise PortLost(str(exc)) from exc + + +def serve(open_port, out, key_source=None, max_lines=None): + """Read device lines until STOP, max_lines protocol lines, or the opener is done. + + open_port() returns a port or None. A port raises PortLost when the cable drops. + """ + if key_source is None: + key_source = lambda: None + state = new_state() + out.write(startup_text()) + out.write("\n") + out.write(prep_text()) + out.write("\n") + out.flush() + port = None + pending = b"" + seen = 0 + painted = {"screen": None} + + def emit(screen): + if screen == painted["screen"]: + return + painted["screen"] = screen + out.write("\n") + out.write(screen + "\n") + out.flush() + + while max_lines is None or seen < max_lines: + if port is None: + try: + port = open_port() + except PortLost: + port = None + if port is None: + if max_lines is not None: + break + time.sleep(0.3) + continue + try: + raw = read_chunk(port) + except PortLost: + port = None + pending = b"" + continue + if raw: + pending += raw + changed = False + while b"\n" in pending and (max_lines is None or seen < max_lines): + chunk, pending = pending.split(b"\n", 1) + line = chunk.decode("utf-8", "replace") + if not feed_line(state, line): + continue + text = line.strip() + changed = True + seen += 1 + if text == "STOP": + if changed and state.get("echo", True): + emit(display(state)) + return state + if changed and state.get("echo", True): + emit(display(state)) + key = key_source() + if key and port is not None: + try: + port.write(encode_key(key)) + except OSError: + port = None + pending = b"" + if max_lines is None and not raw and key is None and not hasattr(port, "fileno"): + time.sleep(0.02) + return state + + +def cdc_devices(list_ports): + found = [] + for port in list_ports: + if getattr(port, "vid", None) == ESPRESSIF_VID and getattr(port, "device", None): + found.append(port.device) + return found + + +def port_open_message(exc): + text = str(exc).lower() + if "busy" in text or "permission" in text or "access is denied" in text: + return ( + "Port is busy. Close the other program using the board. " + "This script will keep waiting." + ) + return "Port did not open. Unplug the board and plug it back in." + + +def open_cdc(explicit, list_ports, serial_module): + if explicit: + return open_serial(serial_module, explicit) + devices = cdc_devices(list_ports()) + if len(devices) != 1: + return None, devices + return open_serial(serial_module, devices[0]), devices + + +def open_serial(serial_module, device): + port = serial_module.Serial() + port.port = device + port.baudrate = 115200 + port.timeout = 0 + port.write_timeout = 1 + # Leave DTR and RTS low so opening the port does not reset the module. + port.dtr = False + port.rts = False + port.open() + # One byte marks the USB link up. It is not Enter. + try: + port.write(b"?") + except OSError: + pass + return port + + +def read_key_nonblocking(): + if os.name == "nt": + import msvcrt + + if not msvcrt.kbhit(): + return None + return windows_key(msvcrt.getwch(), msvcrt.getwch) + import select + + if not select.select([sys.stdin], [], [], 0)[0]: + return None + return token_for_char(sys.stdin.read(1)) + + +def configure_stdin(): + if os.name == "nt" or not sys.stdin.isatty(): + return None + import termios + import tty + + fd = sys.stdin.fileno() + previous = termios.tcgetattr(fd) + tty.setcbreak(fd) + return previous + + +def restore_stdin(previous): + if previous is None: + return + import termios + + termios.tcsetattr(sys.stdin.fileno(), termios.TCSADRAIN, previous) + + +def main(argv=None): + parser = argparse.ArgumentParser(description="PCBA test host") + parser.add_argument("--port", help="CDC serial device") + args = parser.parse_args(argv) + try: + import serial + from serial.tools import list_ports + except ImportError: + sys.stderr.write("Install pyserial: python3 -m pip install pyserial\n") + return 1 + + announced = {"waiting": False} + + def open_port(): + try: + opened, devices = open_cdc(args.port, list_ports.comports, serial) + except serial.SerialException as exc: + text = port_open_message(exc) + if announced.get("error") != text: + sys.stdout.write("\n%s\n" % text) + sys.stdout.flush() + announced["error"] = text + return None + if opened is not None: + announced["waiting"] = False + announced["error"] = None + return opened + if not announced["waiting"]: + if devices: + sys.stdout.write("CDC ports: %s\n" % ", ".join(devices)) + sys.stdout.flush() + announced["waiting"] = True + return None + + previous = configure_stdin() + try: + serve(open_port, sys.stdout, key_source=read_key_nonblocking) + except KeyboardInterrupt: + return 0 + finally: + restore_stdin(previous) + return 0 + + +if __name__ == "__main__": + sys.exit(main()) diff --git a/scripts/test_pcba_test.py b/scripts/test_pcba_test.py new file mode 100644 index 00000000..ab108173 --- /dev/null +++ b/scripts/test_pcba_test.py @@ -0,0 +1,341 @@ +#!/usr/bin/env python3 +"""Host checks for scripts/pcba_test.py. Does not flash.""" + +import io +import sys +import unittest +from pathlib import Path + +sys.path.insert(0, str(Path(__file__).resolve().parent)) + +from pcba_test import ( # noqa: E402 + BOARD_REV, + FIRMWARE_DOC, + FIRMWARE_LINE, + PortLost, + STEPS, + WEB_TESTER, + display, + port_open_message, + encode_key, + windows_key, + feed_line, + new_state, + next_action_text, + serve, + prep_text, + startup_text, +) + +ROOT = Path(__file__).resolve().parents[1] +CARD = ROOT / "docs" / "hardware" / "pcba-test.md" + + +class FakePort: + def __init__(self, lines, drop_when_empty=False): + self.lines = list(lines) + self.drop_when_empty = drop_when_empty + self.writes = [] + + def readline(self): + if not self.lines: + if self.drop_when_empty: + raise PortLost("cable") + return b"" + return (self.lines.pop(0) + "\n").encode() + + def write(self, data): + self.writes.append(data) + + +def play(script): + state = new_state() + shown = [] + writes = [] + for kind, value in script: + if kind == "line": + feed_line(state, value) + shown.append(display(state)) + else: + writes.append(encode_key(value)) + return shown, writes, state + + +class HostTests(unittest.TestCase): + def test_windows_key_ignores_unmapped_and_extended(self): + extra = [] + + def read_extended(): + extra.append("scan") + + for ch in ("x", " ", "\x03"): + extra.clear() + self.assertIsNone(windows_key(ch, read_extended)) + self.assertEqual(extra, []) + + for prefix in ("\x00", "\xe0"): + extra.clear() + self.assertIsNone(windows_key(prefix, read_extended)) + self.assertEqual(extra, ["scan"]) + + self.assertEqual(windows_key("\r", read_extended), "enter") + self.assertEqual(windows_key("n", read_extended), "n") + self.assertEqual(windows_key("+", read_extended), "+") + + def test_busy_port_waits_without_a_traceback(self): + self.assertIn("Port is busy", port_open_message(OSError("Resource busy"))) + self.assertIn("keep waiting", port_open_message(OSError("[Errno 16] Resource busy"))) + + def open_port(): + raise PortLost("could not open port /dev/cu.usbmodem: Resource busy") + + out = io.StringIO() + serve(open_port, out, max_lines=1) + self.assertIn("PREPARE", out.getvalue()) + self.assertNotIn("Traceback", out.getvalue()) + + def test_startup_names_web_tester(self): + self.assertIn(WEB_TESTER, startup_text()) + self.assertIn(BOARD_REV, startup_text()) + self.assertIn(FIRMWARE_LINE, startup_text()) + self.assertIn(FIRMWARE_DOC, startup_text()) + prep = prep_text() + self.assertIn("Take the board.", prep) + self.assertIn("Match the USB mark on the board.", prep) + self.assertIn("Plug the speaker into the JST speaker port.", prep) + self.assertIn("Use the board socket, not the ESP32.", prep) + + def test_connected_board_waits_for_confirmation(self): + port = FakePort(["READY"]) + + def open_port(): + return port + + out = io.StringIO() + serve(open_port, out, max_lines=1) + log = out.getvalue() + self.assertEqual(port.writes, []) + self.assertIn("The board is connected.", log) + self.assertIn("Enter = continue", log) + self.assertNotIn("1/3", log) + + def test_ready_waits_for_the_operator(self): + shown, _writes, _state = play([("line", "READY")]) + self.assertIn("CONNECTED", shown[0]) + self.assertIn("The board is connected.", shown[0]) + self.assertIn("Enter = continue", shown[0]) + self.assertNotIn("speaker", shown[0].lower()) + self.assertNotIn("1/3", shown[0]) + + def test_accept_path_and_fail_menu(self): + shown, writes, state = play( + [ + ("line", "PCBA-TEST v1"), + ("line", "STEP tone"), + ("key", "enter"), + ("line", "STEP servos"), + ("line", "STEP oe"), + ("line", "RESULT PASS"), + ] + ) + self.assertIn("1/3", shown[1]) + self.assertIn("SPEAKER", shown[1]) + self.assertIn("Speaker on the JST speaker port.", shown[1]) + self.assertNotIn("Lamps do not count.", shown[1]) + self.assertIn("Expect a repeating tone.", shown[1]) + self.assertNotIn("STEP tone", shown[1]) + self.assertIn("Volume 6/10.", shown[1]) + self.assertIn("+ = louder", shown[1]) + self.assertIn("- = quieter", shown[1]) + self.assertIn("Enter = good", shown[1]) + self.assertIn("n = bad", shown[1]) + self.assertIn("├", shown[1]) + self.assertIn("2/3", shown[2]) + self.assertIn("SERVOS", shown[2]) + self.assertNotIn("+ = louder", shown[2]) + self.assertNotIn("Volume", shown[2]) + self.assertIn("Signal is on all five servo outputs.", shown[2]) + self.assertIn("Plug it into one column at a time.", shown[2]) + self.assertIn("Columns are HEAD, NECK, ARM L, ARM R, and BODY.", shown[2]) + self.assertIn("Check the LEDs on every column.", shown[2]) + self.assertIn("Red stays on and yellow pulses.", shown[2]) + self.assertNotIn("No key between columns.", shown[2]) + self.assertNotIn("STEP servos", shown[2]) + self.assertIn("3/3", shown[3]) + self.assertIn("OE OUTPUT ENABLE", shown[3]) + self.assertIn("The red LED stays on.", shown[3]) + self.assertIn("Only the yellow LED goes out.", shown[3]) + self.assertIn("No need to test each servo column.", shown[3]) + self.assertNotIn("PWM", shown[3]) + self.assertNotIn("5 V", shown[3]) + self.assertNotIn("STEP oe", shown[3]) + self.assertIn("├", shown[2]) + self.assertEqual(writes, [b"\n"]) + self.assertEqual(encode_key("+"), b"+") + self.assertEqual(encode_key("="), b"+") + self.assertEqual(encode_key("-"), b"-") + louder, _writes, louder_state = play([("line", "STEP tone"), ("line", "VOL 8")]) + self.assertIn("Volume 8/10.", louder[1]) + self.assertEqual(louder_state["volume"], 8) + self.assertIn("RESULT PASS", shown[-1]) + + shown, writes, _state = play( + [ + ("line", "STEP servos"), + ("key", "n"), + ("line", "FAIL servos"), + ("key", "c"), + ] + ) + self.assertIn("2/3", shown[0]) + self.assertNotIn("STEP servos", shown[0]) + self.assertIn("Red stays on and yellow pulses.", shown[1]) + self.assertIn("r = try this step again", shown[1]) + self.assertIn("c = keep the fail, go on", shown[1]) + self.assertIn("a = start this board over", shown[1]) + self.assertIn("FAIL servos", shown[1]) + self.assertEqual(writes, [b"n", b"c"]) + + banner, _writes, _state = play([("line", "PCBA-TEST v1")]) + self.assertIn( + "The module LED stays steady white while the test image has power. That lamp is not the board verdict.", + banner[0], + ) + self.assertIn("PCBA-TEST v1", banner[0]) + + pca, _writes, _state = play([("line", "FAIL pca")]) + self.assertIn("PCA9685 did not answer.", pca[0]) + self.assertIn("This board fails before the speaker test.", pca[0]) + self.assertNotIn("r = try this step again", pca[0]) + self.assertNotIn("c = keep the fail, go on", pca[0]) + self.assertNotIn("a = start this board over", pca[0]) + + page = (ROOT / "web" / "js" / "pcba-test.mjs").read_text() + script = (ROOT / "scripts" / "pcba_test.py").read_text() + for _name, _title, sentence in STEPS: + self.assertIn(sentence, page) + self.assertIn(sentence, script) + + def test_reconnect_shows_the_next_session(self): + ports = [ + FakePort(["RESULT FAIL tone body"], drop_when_empty=True), + FakePort(["PCBA-TEST v1"]), + ] + + def open_port(): + if not ports: + return None + return ports.pop(0) + + out = io.StringIO() + state = serve(open_port, out, max_lines=2) + log = out.getvalue() + + self.assertIn("RESULT FAIL tone body", log) + self.assertIn("PCBA-TEST v1", state["shown"]) + + def test_write_oserror_opens_the_next_port(self): + class WriteFails(FakePort): + def write(self, data): + raise OSError("device disconnected") + + ports = [ + WriteFails(["READY"]), + FakePort(["PCBA-TEST v1"]), + ] + keys = iter(["q"]) + + def open_port(): + if not ports: + return None + return ports.pop(0) + + def key_source(): + return next(keys, None) + + out = io.StringIO() + state = serve(open_port, out, key_source=key_source, max_lines=2) + + self.assertNotIn("Traceback", out.getvalue()) + self.assertIn("PCBA-TEST v1", state["shown"]) + + def test_result_says_what_to_do_and_stop_returns(self): + port = FakePort(["RESULT PASS", "STOP"]) + + def open_port(): + return port + + out = io.StringIO() + serve(open_port, out) + log = out.getvalue() + self.assertIn("RESULT PASS", log) + self.assertIn(next_action_text().strip(), log) + self.assertIn("STOP", log) + + def test_scripted_sessions_match_the_card(self): + pass_shown, _writes, _state = play( + [ + ("line", "STEP tone"), + ("key", "enter"), + ("line", "STEP servos"), + ("key", "enter"), + ("line", "RESULT PASS"), + ] + ) + fail_shown, fail_writes, _state = play( + [ + ("line", "STEP tone"), + ("key", "n"), + ("line", "FAIL tone"), + ("key", "c"), + ("line", "STEP servos"), + ("key", "n"), + ("line", "FAIL servos"), + ("key", "c"), + ("line", "RESULT FAIL tone servos"), + ] + ) + self.assertIn("RESULT PASS", pass_shown[-1]) + self.assertIn("RESULT FAIL tone servos", fail_shown[-1]) + self.assertIn(b"n", fail_writes) + self.assertIn(b"c", fail_writes) + + card = CARD.read_text() + for phrase in ( + "tone", + "servos", + "HEAD", + "NECK", + "ARM L", + "ARM R", + "BODY", + "testing board", + "oe", + "+ = louder", + "- = quieter", + "Only the yellow LED goes out", + "No need to test each servo column", + "RESULT PASS", + "RESULT FAIL tone servos", + "python3 scripts/pcba_test.py", + WEB_TESTER, + "main control board rev 3", + "Red stays on and yellow pulses", + "square pad as GND", + "J1", + "golden module stays with the tester", + "The ESP32 must already run the test firmware", + "pio run -e pcba-test -t upload", + "The product firmware cannot run this test", + "J2", + "OLED", + "Wi-Fi", + "2 A load", + ): + self.assertIn(phrase, card) + for key in ("r", "c", "a", "n", "q"): + self.assertIn("`%s`" % key, card) + + +if __name__ == "__main__": + unittest.main() diff --git a/scripts/test_pcba_web.mjs b/scripts/test_pcba_web.mjs new file mode 100644 index 00000000..89f23b23 --- /dev/null +++ b/scripts/test_pcba_web.mjs @@ -0,0 +1,267 @@ +import assert from "node:assert/strict"; +import { readdir, readFile } from "node:fs/promises"; +import path from "node:path"; +import { fileURLToPath } from "node:url"; + +import { + PYTHON_COMMAND, + canTest, + createHost, + PORT_LOST, + activatePort, + releasePort, + display, + encodeKey, + acceptKeyEvent, + keyToken, + feed, + grant, + connectTarget, + prepText, + splitCard, + onDisconnect, + onPortReturn, +} from "../web/js/pcba-test.mjs"; + +const root = path.resolve(path.dirname(fileURLToPath(import.meta.url)), ".."); +const webRoot = path.join(root, "web"); + +function assertGate() { + assert.equal( + canTest({ isSecureContext: true, navigator: {} }), + false + ); + assert.equal( + canTest({ isSecureContext: false, navigator: { serial: {} } }), + false + ); + assert.equal( + canTest({ isSecureContext: true, navigator: { serial: {} } }), + true + ); +} + +async function walkHtml(dir, found = []) { + const entries = await readdir(dir, { withFileTypes: true }); + for (const entry of entries) { + const full = path.join(dir, entry.name); + if (entry.isDirectory()) { + await walkHtml(full, found); + } else if (entry.name.endsWith(".html")) { + found.push(full); + } + } + return found; +} + +async function assertNoInboundLinks() { + const files = await walkHtml(webRoot); + const page = path.join(webRoot, "pcba_test", "index.html"); + for (const file of files) { + if (file === page) { + continue; + } + const text = await readFile(file, "utf8"); + assert.equal(text.includes("pcba_test"), false, file); + } + const html = await readFile(page, "utf8"); + assert.match(html, /Compatible with main control board rev 3/); + assert.match(html, /The ESP32 must already run the test firmware/); + assert.match( + html, + /https:\/\/github.com\/jamro\/tiny-engineer\/blob\/main\/docs\/hardware\/pcba-test\.md#get-an-esp32-with-the-test-firmware/ + ); + assert.match(html, /This browser cannot run the test/); + assert.match( + html, + /https:\/\/github.com\/jamro\/tiny-engineer\/blob\/main\/docs\/hardware\/pcba-test\.md/ + ); + assert.match(html, new RegExp(PYTHON_COMMAND.replace(/[.]/g, "\\."))); + assert.match(html, /id="connect"[^>]*hidden/); + assert.match(html, /id="disconnect"[^>]*hidden/); + assert.equal(html.includes("Save CSV"), false); + assert.equal(html.includes('id="save"'), false); +} + +function assertSession() { + const host = createHost(); + grant(host); + feed(host, "READY"); + assert.match(display(host), /CONNECTED/); + assert.match(display(host), /The board is connected/); + assert.match(display(host), /Enter = continue/); + assert.doesNotMatch(display(host), /speaker/i); + assert.doesNotMatch(display(host), /1\/3/); + feed(host, "PCBA-TEST v1"); + assert.match(display(host), /The module LED stays steady white while the test image has power/); + assert.match(display(host), /That lamp is not the board verdict/); + assert.match(display(host), /PCBA-TEST v1/); + feed(host, "STEP tone"); + assert.match(display(host), /1\/3/); + assert.match(display(host), /SPEAKER/); + assert.match(display(host), /Speaker on the JST speaker port/); + assert.doesNotMatch(display(host), /Lamps do not count/); + assert.match(display(host), /Expect a repeating tone/); + assert.match(display(host), /Volume 6\/10/); + assert.match(display(host), /\+ = louder/); + assert.match(display(host), /- = quieter/); + assert.match(display(host), /Enter = good/); + assert.match(display(host), /n = bad/); + assert.doesNotMatch(display(host), /STEP tone/); + feed(host, "STEP servos"); + assert.match(display(host), /2\/3/); + assert.match(display(host), /SERVOS/); + assert.doesNotMatch(display(host), /\+ = louder/); + assert.doesNotMatch(display(host), /Volume/); + assert.match(display(host), /Signal is on all five servo outputs/); + assert.match(display(host), /Plug it into one column at a time/); + assert.match(display(host), /Columns are HEAD, NECK, ARM L, ARM R, and BODY/); + assert.match(display(host), /Check the LEDs on every column/); + assert.match(display(host), /Red stays on and yellow pulses/); + assert.doesNotMatch(display(host), /No key between columns/); + assert.doesNotMatch(display(host), /STEP servos/); + feed(host, "STEP oe"); + assert.match(display(host), /3\/3/); + assert.match(display(host), /OE OUTPUT ENABLE/); + assert.match(display(host), /The red LED stays on/); + assert.match(display(host), /Only the yellow LED goes out/); + assert.match(display(host), /No need to test each servo column/); + assert.doesNotMatch(display(host), /PWM/); + assert.doesNotMatch(display(host), /5 V/); + assert.doesNotMatch(display(host), /STEP oe/); + assert.equal(keyToken("Enter"), "enter"); + assert.equal(encodeKey(keyToken("Enter")), "\n"); + assert.equal(encodeKey(keyToken("+")), "+"); + assert.equal(encodeKey(keyToken("n")), "n"); + assert.equal(encodeKey("enter"), "\n"); + assert.equal(encodeKey("n"), "n"); + assert.equal(encodeKey("+"), "+"); + assert.equal(encodeKey("="), "+"); + assert.equal(encodeKey("-"), "-"); + assert.equal(acceptKeyEvent({ key: "Enter", repeat: true }), ""); + assert.equal(acceptKeyEvent({ key: "a", ctrlKey: true }), ""); + assert.equal(acceptKeyEvent({ key: "a", metaKey: true }), ""); + assert.equal(acceptKeyEvent({ key: "r", altKey: true }), ""); + assert.equal(acceptKeyEvent({ key: "Enter" }), "\n"); + assert.equal(acceptKeyEvent({ key: "a" }), "a"); + assert.equal(acceptKeyEvent({ key: "+", shiftKey: true }), "+"); + feed(host, "STEP tone"); + feed(host, "VOL 8"); + assert.match(display(host), /Volume 8\/10/); + feed(host, "FAIL servos"); + assert.match(display(host), /Red stays on and yellow pulses/); + assert.match(display(host), /r = try this step again/); + assert.match(display(host), /c = keep the fail, go on/); + assert.match(display(host), /a = start this board over/); + assert.match(display(host), /FAIL servos/); + feed(host, "FAIL pca"); + assert.match(display(host), /PCA9685 did not answer/); + assert.match(display(host), /This board fails before the speaker test/); + assert.doesNotMatch(display(host), /r = try this step again/); + assert.doesNotMatch(display(host), /c = keep the fail, go on/); + assert.doesNotMatch(display(host), /a = start this board over/); + feed(host, "RESULT PASS"); + assert.match(display(host), /RESULT PASS/); + const asks = host.grantAsks; + onDisconnect(host); + assert.equal(host.connected, false); + assert.equal(onPortReturn(host), true); + assert.equal(host.grantAsks, asks); + assert.equal(host.connected, true); + + const fresh = createHost(); + assert.equal(onPortReturn(fresh), false); + assert.equal(fresh.grantAsks, 1); +} + +function assertConnectAsksAgain() { + const port = { readable: {} }; + assert.equal(connectTarget(port, true), port); + assert.equal(connectTarget(port, false), null); +} + +function assertCardSplit() { + const prep = splitCard(prepText()); + assert.equal(prep.title, "PREPARE"); + assert.equal(prep.keys.length, 0); + assert.equal(prep.body[0].n, "1"); + assert.equal(prep.body[0].text, "Take the board."); + const tone = splitCard( + "1/3 SPEAKER\n\nSpeaker on the JST speaker port.\nExpect a repeating tone.\nVolume 6/10.\n\n+ = louder\n- = quieter\nEnter = good\nn = bad" + ); + assert.equal(tone.title, "1/3 SPEAKER"); + assert.deepEqual(tone.keys.map((item) => item.key), ["+", "-", "Enter", "n"]); + assert.equal(tone.body.some((item) => item.text.startsWith("Volume")), true); +} + +async function assertActivatePort() { + const prep = prepText(); + assert.match(prep, /PREPARE/); + assert.match(prep, /Take the board/); + assert.match(prep, /JST speaker port/); + assert.match(prep, /not the ESP32/); + const signals = []; + const writes = []; + let closed = 0; + const port = { + readable: {}, + writable: { + getWriter() { + return { + async write(data) { + writes.push(Array.from(data)); + }, + releaseLock() {}, + }; + }, + }, + async open() { + this.readable = {}; + }, + async close() { + closed += 1; + this.readable = null; + this.writable = this.writable; + }, + async setSignals(value) { + signals.push(value); + }, + }; + const released = { closed: 0, cancelled: 0 }; + const live = { + readable: {}, + writable: {}, + async close() { + released.closed += 1; + this.readable = null; + this.writable = null; + }, + }; + const session = { + reader: { + async cancel() { + released.cancelled += 1; + }, + releaseLock() {}, + }, + }; + await releasePort(live, session); + assert.equal(released.cancelled, 1); + assert.equal(released.closed, 1); + assert.equal(session.closing, true); + assert.equal(session.connected, false); + assert.equal(session.reader, null); + await activatePort(port); + assert.equal(closed, 1); + assert.deepEqual(signals, [{ dataTerminalReady: false, requestToSend: false }]); + assert.deepEqual(writes, [[0x3f]]); + assert.match(PORT_LOST, /press Connect again/); +} + +assertGate(); +await assertNoInboundLinks(); +assertSession(); +assertCardSplit(); +assertConnectAsksAgain(); +await assertActivatePort(); +console.log("pcba web ok"); diff --git a/web/js/pcba-test.mjs b/web/js/pcba-test.mjs new file mode 100644 index 00000000..a8f34aa6 --- /dev/null +++ b/web/js/pcba-test.mjs @@ -0,0 +1,732 @@ +export const WEB_TESTER = "https://tinyengineer.dev/pcba_test"; +export const PYTHON_COMMAND = "python3 scripts/pcba_test.py"; +export const INCOMPATIBLE = + "This browser cannot run the test. Use " + PYTHON_COMMAND; + +export function canTest(scope) { + return Boolean( + scope && + scope.isSecureContext && + scope.navigator && + scope.navigator.serial + ); +} + +export function createHost() { + return { + shown: "", + menu: false, + volume: 6, + step: "", + granted: false, + connected: false, + grantAsks: 0, + heard: false, + opening: false, + reopenTries: 0, + session: 0, + }; +} + +export function connectTarget(port, connected) { + return connected ? port : null; +} + +export function prepText() { + return [ + "PREPARE", + "", + "1 Take the board.", + "2 Plug in the ESP32.", + " Match the USB mark on the board.", + "3 Plug the speaker into the JST speaker port.", + "4 Connect USB to the board.", + " Use the board socket, not the ESP32.", + ].join("\n"); +} + +export const PORT_LOST = "Port lost. Unplug the board and press Connect again."; + +export async function releasePort(port, host) { + if (host) { + host.closing = true; + host.connected = false; + } + const reader = host && host.reader; + if (reader) { + try { + await reader.cancel(); + } catch (_err) { + // The stream already ended. + } + try { + reader.releaseLock(); + } catch (_err) { + // Lock already released. + } + host.reader = null; + } + if (port && (port.readable || port.writable)) { + try { + await port.close(); + } catch (_err) { + // The port dropped before close. + } + } +} + +export async function activatePort(port) { + if (port.readable || port.writable) { + try { + await port.close(); + } catch (_err) { + // Already closed after a USB reset. + } + } + await port.open({ baudRate: 115200 }); + if (port.setSignals) { + await port.setSignals({ dataTerminalReady: false, requestToSend: false }); + } + const writer = port.writable.getWriter(); + try { + await writer.write(new Uint8Array([0x3f])); + } finally { + writer.releaseLock(); + } +} + +export function grant(host) { + host.granted = true; + host.connected = true; +} + +export function onDisconnect(host) { + host.connected = false; +} + +export function onPortReturn(host) { + if (!host.granted) { + host.grantAsks += 1; + return false; + } + host.connected = true; + return true; +} + +const READY_COACH = "The board is connected."; +const BANNER_COACH = + "The module LED stays steady white while the test image has power. That lamp is not the board verdict."; +const PCA_COACH = "PCA9685 did not answer. This board fails before the speaker test."; +const WAIT_KEYS = "Enter = good\nn = bad"; +const TONE_KEYS = "+ = louder\n- = quieter"; +const TONE_LEVELS = 10; +const TONE_LEVEL_DEFAULT = 6; +const FAIL_KEYS = "r = try this step again\nc = keep the fail, go on\na = start this board over"; +const STEPS = [ + ["tone", "SPEAKER", "Speaker on the JST speaker port. Expect a repeating tone."], + [ + "servos", + "SERVOS", + "Signal is on all five servo outputs. Take the testing board. Plug it into one column at a time. Columns are HEAD, NECK, ARM L, ARM R, and BODY. Check the LEDs on every column. Red stays on and yellow pulses.", + ], + [ + "oe", + "OE OUTPUT ENABLE", + "The red LED stays on. Only the yellow LED goes out. No need to test each servo column.", + ], +]; + +function stepSentence(name) { + const found = STEPS.find((row) => row[0] === name); + return found ? found[2] : ""; +} + +function stepTitle(name) { + const found = STEPS.find((row) => row[0] === name); + return found ? found[1] : name; +} + +function prose(text) { + return text + .split(". ") + .filter(Boolean) + .map((part) => (part.endsWith(".") ? part : part + ".")) + .join("\n"); +} + +function coachStep(name, volume) { + const index = STEPS.findIndex((row) => row[0] === name); + const body = `${index + 1}/${STEPS.length} ${stepTitle(name)}\n\n${prose(stepSentence(name))}`; + if (name !== "tone") { + return `${body}\n\n${WAIT_KEYS}`; + } + const level = volume == null ? TONE_LEVEL_DEFAULT : volume; + return `${body}\nVolume ${level}/${TONE_LEVELS}.\n\n${TONE_KEYS}\n${WAIT_KEYS}`; +} + +function coachFail(name, token) { + if (name === "pca") { + return `PCA\n\n${prose(PCA_COACH)}\n\n${token}`; + } + const sentence = stepSentence(name); + if (!sentence) { + return token; + } + return `${stepTitle(name)}\n\n${prose(sentence)}\n\n${FAIL_KEYS}\n\n${token}`; +} + +export function feed(host, line) { + const text = String(line || "").trim(); + if (!text) { + return false; + } + host.heard = true; + host.reopenTries = 0; + if (text.startsWith("STEP ")) { + const name = text.slice(5); + host.step = name; + host.shown = stepSentence(name) ? coachStep(name, host.volume) : text; + host.menu = false; + } else if (text.startsWith("VOL ")) { + const level = Number(text.slice(4)); + if (!Number.isInteger(level) || level < 1 || level > TONE_LEVELS) { + return false; + } + host.volume = level; + if (host.step === "tone") { + host.shown = coachStep("tone", level); + } + host.menu = false; + } else if (text.startsWith("FAIL ")) { + const name = text.slice(5); + host.shown = coachFail(name, text); + host.menu = Boolean(stepSentence(name)); + } else if (text.startsWith("RESULT ")) { + host.shown = text; + host.menu = false; + } else if (text === "READY") { + host.shown = `CONNECTED\n\n${prose(READY_COACH)}\n\nEnter = continue`; + host.menu = false; + } else if (text.startsWith("PCBA-TEST")) { + host.shown = `${BANNER_COACH}\n${text}`; + host.menu = false; + } else if (text === "STOP") { + host.shown = text; + host.menu = false; + } else { + return false; + } + return true; +} + +export function display(host) { + return host.shown; +} + +export function splitCard(text) { + const lines = String(text || "").split("\n"); + const keys = []; + const body = []; + let title = ""; + for (const raw of lines) { + const line = raw.trim(); + if (!line) { + continue; + } + const key = line.match(/^(\S+)\s+=\s+(.+)$/); + if (key && key[1].length <= 12 && !key[1].includes(".")) { + keys.push({ key: key[1], label: key[2] }); + continue; + } + if (!title) { + if (line.length > 48) { + title = "BOARD"; + body.push({ kind: "line", text: line }); + } else { + title = line; + } + continue; + } + const step = line.match(/^(\d+)\s{2,}(.+)$/); + if (step) { + body.push({ kind: "step", n: step[1], text: step[2] }); + continue; + } + if (raw.startsWith(" ")) { + body.push({ kind: "note", text: line }); + continue; + } + const kind = line === PORT_LOST || line.startsWith("FAIL ") || line.startsWith("RESULT FAIL") + ? "alert" + : "line"; + body.push({ kind, text: line }); + } + return { title: title || "PREPARE", body, keys }; +} + +export function keyToken(label) { + return label === "Enter" ? "enter" : label; +} + +export function encodeKey(key) { + if (key === "enter") { + return "\n"; + } + if (key === "+" || key === "=") { + return "+"; + } + if (key === "n" || key === "r" || key === "c" || key === "a" || key === "q" || key === "-") { + return key; + } + return ""; +} + +export function acceptKeyEvent(event) { + if (event.repeat || event.ctrlKey || event.metaKey || event.altKey) { + return ""; + } + const key = event.key === "Enter" ? "enter" : event.key; + return encodeKey(key); +} + +function ledClass(card, text) { + if (text.includes(PORT_LOST) || text.includes("RESULT FAIL") || text.includes("FAIL ")) { + return "led led-err"; + } + if (text.includes("RESULT PASS")) { + return "led led-ok"; + } + if (card.title === "CONNECTED" || /^\d\/\d/.test(card.title)) { + return "led led-ok led-pulse"; + } + return "led led-warn"; +} + +function lineRole(text) { + if (text.startsWith("Volume ")) { + return "meta"; + } + if (text.startsWith("No need")) { + return "aside"; + } + if (text.startsWith("Columns are ")) { + return "columns"; + } + if ( + text.startsWith("Expect ") || + text.startsWith("Check the LEDs") || + text.startsWith("Red stays") || + text.startsWith("The red LED") || + text.startsWith("Only the yellow") + ) { + return "look"; + } + return "line"; +} + +function columnList() { + const wrap = document.createElement("div"); + wrap.className = "pcba-columns"; + const caption = document.createElement("p"); + caption.className = "pcba-columns-label"; + caption.textContent = "Columns"; + const list = document.createElement("ol"); + for (const name of ["HEAD", "NECK", "ARM L", "ARM R", "BODY"]) { + const item = document.createElement("li"); + item.textContent = name; + list.appendChild(item); + } + wrap.append(caption, list); + return wrap; +} + +function paintBody(step, items) { + step.replaceChildren(); + let index = 0; + while (index < items.length) { + const item = items[index]; + if (item.kind === "step") { + const p = document.createElement("p"); + p.className = "pcba-step"; + const n = document.createElement("span"); + n.className = "pcba-step-n"; + n.textContent = item.n; + const label = document.createElement("span"); + label.textContent = item.text; + p.append(n, label); + step.appendChild(p); + index += 1; + continue; + } + const role = item.kind === "line" ? lineRole(item.text) : item.kind; + if (role === "look") { + const box = document.createElement("div"); + box.className = "pcba-look"; + while (index < items.length && items[index].kind === "line" && lineRole(items[index].text) === "look") { + const p = document.createElement("p"); + p.textContent = items[index].text; + box.appendChild(p); + index += 1; + } + step.appendChild(box); + continue; + } + if (role === "columns") { + step.appendChild(columnList()); + index += 1; + continue; + } + const p = document.createElement("p"); + p.className = role === "note" ? "pcba-note" : role === "aside" ? "pcba-aside" : role === "alert" ? "pcba-alert" : role === "meta" ? "pcba-meta" : "pcba-line"; + p.textContent = item.text; + step.appendChild(p); + index += 1; + } +} + +function render(host) { + const step = document.getElementById("step"); + const title = document.getElementById("pcba-title"); + const keys = document.getElementById("pcba-keys"); + const led = document.getElementById("pcba-led"); + const text = display(host) || prepText(); + const card = splitCard(text); + if (title) { + title.textContent = card.title; + } + if (step) { + const signature = card.body.map((item) => item.kind + "\n" + item.text).join("\n"); + if (step.dataset.sig !== signature) { + step.dataset.sig = signature; + paintBody(step, card.body); + } + } + if (keys) { + const signature = card.keys.map((item) => item.key + "\n" + item.label).join("\n") + + (host.connected ? "\n1" : "\n0"); + keys.hidden = card.keys.length === 0; + if (keys.dataset.sig !== signature) { + keys.dataset.sig = signature; + keys.replaceChildren(); + card.keys.forEach((item) => { + const row = document.createElement("p"); + const button = document.createElement("button"); + button.type = "button"; + button.className = "pcba-key"; + button.dataset.key = keyToken(item.key); + button.textContent = item.key; + button.disabled = !host.connected; + if (button.dataset.key === "enter") { + row.className = "pcba-key-default"; + } + row.append(button, document.createTextNode(item.label)); + keys.appendChild(row); + }); + } + } + if (led) { + led.className = ledClass(card, text); + } +} + +function delay(ms) { + return new Promise((resolve) => setTimeout(resolve, ms)); +} + +function showConnect() { + if (typeof document === "undefined") { + return; + } + const connect = document.getElementById("connect"); + const disconnect = document.getElementById("disconnect"); + if (connect) { + connect.hidden = false; + connect.disabled = false; + } + if (disconnect) { + disconnect.hidden = true; + } +} + +function showLost(host) { + onDisconnect(host); + host.opening = false; + host.shown = `${prepText()}\n\n${PORT_LOST}`; + render(host); + showConnect(); +} + +function armWatch(host) { + clearTimeout(host.watch); + const session = host.session; + host.watch = setTimeout(() => { + if (!host.heard && host.session === session) { + showLost(host); + } + }, 2000); +} + +async function readLoop(port, host) { + const session = host.session; + let reader; + try { + reader = port.readable.getReader(); + host.reader = reader; + } catch (_err) { + if (host.session === session) { + await recover(port, host); + } + return; + } + const decoder = new TextDecoder(); + let buffer = ""; + let lost = false; + try { + while (true) { + const { value, done } = await reader.read(); + if (done) { + lost = true; + break; + } + buffer += decoder.decode(value, { stream: true }); + let nl = buffer.indexOf("\n"); + while (nl >= 0) { + const line = buffer.slice(0, nl).replace(/\r$/, ""); + buffer = buffer.slice(nl + 1); + feed(host, line); + render(host); + nl = buffer.indexOf("\n"); + } + } + } catch (_err) { + lost = true; + } finally { + if (host.reader === reader) { + host.reader = null; + } + try { + reader.releaseLock(); + } catch (_err) { + // Reader already released after the port dropped. + } + } + if (lost && !host.closing && host.session === session) { + await recover(port, host); + } +} + +function showDisconnect() { + if (typeof document === "undefined") { + return; + } + const connect = document.getElementById("connect"); + const disconnect = document.getElementById("disconnect"); + if (connect) { + connect.hidden = true; + } + if (disconnect) { + disconnect.hidden = false; + } +} + +async function recover(port, host) { + const session = host.session; + if (host.closing) { + return; + } + onDisconnect(host); + if (host.reopenTries >= 2) { + showLost(host); + return; + } + host.reopenTries += 1; + await delay(600); + if (host.session !== session || host.closing) { + return; + } + try { + await openGranted(port, host); + } catch (_err) { + if (host.session === session) { + await recover(port, host); + } + } +} + +async function openGranted(port, host) { + if (host.opening) { + return; + } + const session = host.session; + host.opening = true; + clearTimeout(host.watch); + host.heard = false; + try { + await activatePort(port); + } catch (err) { + if (host.session === session) { + host.connected = false; + host.opening = false; + } + throw err; + } + if (host.session !== session) { + return; + } + host.opening = false; + host.connected = true; + host.granted = true; + if (!host.shown || host.shown.includes(PORT_LOST)) { + host.shown = prepText(); + } + render(host); + showDisconnect(); + readLoop(port, host); + armWatch(host); +} + +function boot() { + if (typeof document === "undefined") { + return; + } + const host = createHost(); + const incompatible = document.getElementById("incompatible"); + const connect = document.getElementById("connect"); + const disconnect = document.getElementById("disconnect"); + let grantedPort = null; + + if (!canTest(window)) { + return; + } + if (incompatible) { + incompatible.hidden = true; + } + if (connect) { + connect.hidden = false; + } + host.shown = prepText(); + render(host); + + connect?.addEventListener("click", async () => { + host.session += 1; + const session = host.session; + host.closing = true; + host.opening = false; + host.reopenTries = 0; + clearTimeout(host.watch); + try { + await releasePort(grantedPort, host); + } catch (_err) { + // The old port is already gone. + } + if (host.session !== session) { + return; + } + host.closing = false; + let port = connectTarget(grantedPort, host.connected); + try { + if (!port) { + port = await navigator.serial.requestPort(); + } + } catch (err) { + if (err && err.name === "NotFoundError") { + return; + } + showLost(host); + return; + } + if (host.session !== session) { + return; + } + grantedPort = port; + try { + await openGranted(port, host); + } catch (_err) { + if (host.session === session) { + await recover(port, host); + } + } + }); + + disconnect?.addEventListener("click", async () => { + disconnect.disabled = true; + clearTimeout(host.watch); + try { + await releasePort(grantedPort, host); + } catch (_err) { + // Refresh anyway. The next load starts from Connect. + } + location.reload(); + }); + + navigator.serial.addEventListener("disconnect", (event) => { + if (event.target === grantedPort) { + onDisconnect(host); + render(host); + } + }); + + navigator.serial.addEventListener("connect", async (event) => { + if (host.opening || host.connected || host.closing || !host.granted) { + return; + } + grantedPort = event.target; + host.session += 1; + const session = host.session; + host.reopenTries = 0; + try { + await openGranted(grantedPort, host); + } catch (_err) { + if (host.session === session) { + await recover(grantedPort, host); + } + } + }); + + let portWrite = Promise.resolve(); + + function writeEncoded(encoded) { + const job = portWrite.then(async () => { + if (!host.connected || !grantedPort?.writable) { + return; + } + const writer = grantedPort.writable.getWriter(); + try { + await writer.write(new TextEncoder().encode(encoded)); + } finally { + writer.releaseLock(); + } + }); + portWrite = job.catch(() => {}); + return job; + } + + document.getElementById("pcba-keys")?.addEventListener("pointerdown", (event) => { + if (event.button !== 0) { + return; + } + const button = event.target.closest("button[data-key]"); + if (!button || button.disabled) { + return; + } + const encoded = encodeKey(button.dataset.key); + if (!encoded) { + return; + } + writeEncoded(encoded); + }); + + document.addEventListener("keydown", (event) => { + if (!host.connected || !grantedPort?.writable) { + return; + } + const encoded = acceptKeyEvent(event); + if (!encoded) { + return; + } + event.preventDefault(); + writeEncoded(encoded); + }); +} + +boot(); diff --git a/web/pcba_test/index.html b/web/pcba_test/index.html new file mode 100644 index 00000000..ed732be2 --- /dev/null +++ b/web/pcba_test/index.html @@ -0,0 +1,61 @@ + + + + + + + PCBA test · Tiny Engineer + + + + + + + +
+
+ + + Tiny Engineer + +
+
+
+

Line test · ESP32-C3

+

Board test

+

Compatible with main control board rev 3. Listen, look, then press the key on the latest card.

+

The ESP32 must already run the test firmware. How to get one.

+
+

This browser cannot run the test. Use python3 scripts/pcba_test.py

+
+
+ +

PREPARE

+
+
+

1Take the board.

+

2Plug in the ESP32.

+

Match the USB mark on the board.

+

3Plug the speaker into the JST speaker port.

+

4Connect USB to the board.

+

Use the board socket, not the ESP32.

+
+
+ +
+ + +
+
+
+
+

Use Chrome or Edge.

+

For the next board, unplug USB first.

+

Same test from a terminal: python3 scripts/pcba_test.py

+

How to run the script

+
+
+
+ + + diff --git a/web/pcba_test/pcba.css b/web/pcba_test/pcba.css new file mode 100644 index 00000000..51130daf --- /dev/null +++ b/web/pcba_test/pcba.css @@ -0,0 +1,286 @@ +.page-pcba .pcba-main { + max-width: 36rem; +} + +.page-pcba .pcba-intro .lede { + max-width: 38rem; +} + +.pcba-card { + gap: 0; + padding: 1.25rem 1.3rem 1.15rem; +} + +.pcba-head { + display: flex; + align-items: center; + gap: 0.75rem; + margin-bottom: 1rem; +} + +.pcba-title { + margin: 0; + font-family: var(--font-mono); + font-size: clamp(1.35rem, 3vw, 1.7rem); + font-weight: 500; + letter-spacing: 0.01em; + line-height: 1.2; +} + +.pcba-body { + display: flex; + flex-direction: column; + gap: 0.75rem; +} + +.pcba-line, +.pcba-note, +.pcba-alert, +.pcba-meta, +.pcba-step { + margin: 0; + font-size: 1.12rem; + line-height: 1.5; +} + +.pcba-note, +.pcba-aside, +.pcba-meta { + color: var(--muted); + font-size: 0.98rem; +} + +.pcba-note { + margin-left: 2.25rem; +} + +.pcba-alert { + color: var(--error); +} + +.pcba-meta { + font-family: var(--font-mono); +} + +.pcba-look { + display: flex; + flex-direction: column; + gap: 0.2rem; + margin: 0; + padding: 0.75rem 0.9rem; + border-left: 3px solid var(--accent); + border-radius: 0 8px 8px 0; + background: var(--accent-dim); +} + +.pcba-look p { + margin: 0; + font-size: 1.12rem; + line-height: 1.45; +} + +.pcba-columns { + display: flex; + flex-direction: column; + gap: 0.4rem; +} + +.pcba-columns-label { + margin: 0; + color: var(--muted); + font-size: 0.78rem; + font-weight: 600; + letter-spacing: 0.06em; + text-transform: uppercase; +} + +.pcba-columns ol { + display: flex; + flex-wrap: wrap; + gap: 0.4rem; + margin: 0; + padding: 0; + list-style: none; +} + +.pcba-columns li { + padding: 0.28rem 0.55rem; + border: 1px solid var(--border-strong); + border-radius: 6px; + background: var(--raised); + font-family: var(--font-mono); + font-size: 0.82rem; +} + +.pcba-alert { + margin-top: 0.85rem; + color: var(--error); +} + +.pcba-step { + display: grid; + grid-template-columns: 1.5rem 1fr; + gap: 0.7rem; + align-items: baseline; + margin-top: 0.45rem; +} + +.pcba-step-n { + font-family: var(--font-mono); + color: var(--accent); +} + +.pcba-bar { + display: flex; + flex-wrap: wrap; + align-items: center; + gap: 0.55rem 0.7rem; + margin-top: 1.05rem; + padding-top: 0.9rem; + border-top: 1px solid var(--border); +} + +.pcba-bar:not(:has(#pcba-keys:not([hidden]))):not(:has(.pcba-actions button:not([hidden]))) { + display: none; +} + +.pcba-keys[hidden], +.pcba-actions .btn[hidden] { + display: none; +} + +.pcba-keys { + display: flex; + flex: 1 1 auto; + flex-wrap: wrap; + align-items: center; + gap: 0.4rem 0.65rem; + margin: 0; + padding: 0; + border: 0; +} + +.pcba-keys p { + display: flex; + align-items: center; + gap: 0.4rem; + margin: 0; + color: var(--muted); + font-size: 0.9rem; +} + +.pcba-key, +.pcba-actions .btn { + appearance: none; + min-height: 2rem; + min-width: 2rem; + padding: 0.28rem 0.7rem; + border: 1px solid var(--border-strong); + border-radius: var(--radius); + background: var(--raised); + color: var(--text); + font-family: var(--font-sans); + font-size: 0.88rem; + font-weight: 500; + line-height: 1.2; + box-shadow: none; + cursor: pointer; +} + +.pcba-key { + font-family: var(--font-mono); + font-size: 0.82rem; + touch-action: manipulation; +} + +.pcba-key:hover, +.pcba-actions .btn:hover { + border-color: #55554c; +} + +.pcba-key:focus-visible, +.pcba-actions .btn:focus-visible { + outline: 2px solid var(--accent); + outline-offset: 2px; +} + +.pcba-key:active, +.pcba-actions .btn:active { + transform: translateY(1px); +} + +.pcba-key:disabled { + cursor: default; + opacity: 0.55; + transform: none; +} + +.pcba-keys .pcba-key-default { + color: var(--text); + font-weight: 500; +} + +.pcba-key[data-key="enter"] { + background: var(--accent); + border-color: #5fd652; + color: #102010; + font-weight: 600; +} + +.pcba-key[data-key="enter"]:hover { + background: #8fff7d; + border-color: #8fff7d; +} + +.pcba-actions { + display: flex; + align-items: center; + margin: 0; +} + +.pcba-actions:has(#disconnect:not([hidden])) { + margin-left: auto; +} + +.pcba-actions:not(:has(button:not([hidden]))) { + display: none; +} + +.pcba-actions .btn-primary { + min-width: 7.5rem; + background: var(--accent); + border-color: #5fd652; + color: #102010; + font-weight: 600; +} + +.pcba-actions .btn-primary:hover { + background: #8fff7d; + border-color: #8fff7d; +} + +.page-pcba #incompatible { + margin: 0 0 1rem; +} + +.page-pcba .pcba-hint { + display: flex; + flex-direction: column; + gap: 0.35rem; + margin: 1rem 0 0; + color: var(--muted); + font-size: 0.88rem; +} + +.page-pcba .pcba-hint p { + margin: 0; +} + +.page-pcba .pcba-hint a, +.page-pcba .pcba-firmware a { + color: var(--accent); +} + +.page-pcba .pcba-firmware { + margin: 0 0 1rem; +}