update to match calibration data handling

apps/customer/src/orisys_customer/app_window.py

@@ -128,6 +128,7 @@ class CustomerMainWindow(QMainWindow):
 
         self.setStatusBar(QStatusBar())
         self.cal_panel.status_message.connect(self.statusBar().showMessage)
+        self.cal_panel.calibration_exported.connect(self._on_calibration_exported)
         self._build_menus()
         self._wire_toolbar()
         self._wire_sensor_picker()
@@ -434,6 +435,13 @@ class CustomerMainWindow(QMainWindow):
         self._apply_panel_visibility()
         self._persist_prefs()
 
+    def _on_calibration_exported(self, path: str) -> None:
+        """Apply newly written force_calibration.json to the running Sensor."""
+        self._ensure_workers()
+        for worker in (self._box_worker, self._finger_worker):
+            if worker is not None and hasattr(worker, "set_pending_calibration"):
+                worker.set_pending_calibration(path)
+
     def _on_finger_3d_toggled(self, visible: bool) -> None:
         if self.sensor_picker.sensor_type() != "finger":
             return

apps/customer/src/orisys_customer/ui/cal_panel.py

@@ -38,6 +38,7 @@ from orisys_app_shared.paths import calibration_export_dir, sensors_dir
 
 class CalPanel(QFrame):
     status_message = pyqtSignal(str)
+    calibration_exported = pyqtSignal(str)  # path applied to running sensor
 
     def __init__(self, parent=None) -> None:
         super().__init__(parent)
@@ -335,4 +336,7 @@ class CalPanel(QFrame):
         if warnings:
             msg += "\n" + t("cal.export_warnings", detail="; ".join(warnings))
         self.status_message.emit(msg)
+        # Prefer the bundle file for live apply so the next Sensor() also sees it.
+        apply_path = local_path if local_path is not None else primary
+        self.calibration_exported.emit(str(apply_path))
         QMessageBox.information(self, t("panels.cal"), msg)

apps/customer/src/orisys_customer/ui/force_plots.py

@@ -9,6 +9,7 @@ from PyQt5.QtWidgets import QFrame, QHBoxLayout, QLabel, QVBoxLayout
 
 from orisys_app_shared.acquisition.constants import FORCE_SAMPLE_RATE_HZ, LOWPASS_CUTOFF_HZ
 from orisys_app_shared.force import MetricHistory
+from orisys_app_shared.force.history import DEFAULT_MAX_FPS
 from orisys_app_shared.i18n import t
 from orisys_app_shared.theme import color
 
@@ -40,6 +41,7 @@ class ForcePlotsPanel(QFrame):
             sample_rate_hz=FORCE_SAMPLE_RATE_HZ,
             lowpass_cutoff_hz=LOWPASS_CUTOFF_HZ,
             y_axis_min_span=0.5,
+            max_fps=DEFAULT_MAX_FPS,
         )
 
         root = QVBoxLayout(self)

shared/src/orisys_app_shared/acquisition/finger_worker.py

@@ -73,6 +73,7 @@ class FingerAcquisitionWorker:
         self._export_dir: Optional[Path] = None
         self._end_reason: Optional[str] = None
         self._phase: str = "idle"
+        self._pending_calibration: Optional[str] = None
 
     @property
     def is_running(self) -> bool:
@@ -142,6 +143,20 @@ class FingerAcquisitionWorker:
             raise RuntimeError("Finger runtime is not running")
         runtime.tactile.reset()
 
+    def set_pending_calibration(self, path: str | Path | None) -> None:
+        """Queue a force_calibration.json path for the acquisition thread."""
+        with self._lock:
+            self._pending_calibration = str(path) if path is not None else None
+
+    def _consume_pending_calibration(self, sensor) -> None:
+        with self._lock:
+            path = self._pending_calibration
+            self._pending_calibration = None
+        if path is None or sensor is None:
+            return
+        if hasattr(sensor, "set_calibration"):
+            sensor.set_calibration(path)
+
     def _set_end_reason(self, reason: str) -> None:
         with self._lock:
             if self._end_reason is None:
@@ -246,6 +261,7 @@ class FingerAcquisitionWorker:
                 none_streak_start = None
                 tactile = runtime.tactile
                 try:
+                    self._consume_pending_calibration(tactile)
                     tactile.compute_deformation(decompose=True, check_motion=False)
                     tactile.compute_contact()
                 except Exception:

shared/src/orisys_app_shared/acquisition/sdk_worker.py

@@ -95,6 +95,8 @@ def _ensure_bgr(img: np.ndarray) -> np.ndarray:
 
 
 def _sensor_force_calibrated(sensor, *, config_ref: str | Path | None = None) -> bool:
+    if getattr(sensor, "force_calibrated", False):
+        return True
     if getattr(sensor, "_force_cal_sensor_name", None) is not None:
         return True
     if config_ref is None:
@@ -226,6 +228,7 @@ class SdkAcquisitionWorker:
         self._video_source: Optional[str | int] = None
         self._end_reason: Optional[str] = None
         self._phase: str = "idle"
+        self._pending_calibration: Optional[str] = None
 
     @property
     def is_running(self) -> bool:
@@ -294,6 +297,20 @@ class SdkAcquisitionWorker:
             raise RuntimeError("Sensor is not running")
         sensor.reset()
 
+    def set_pending_calibration(self, path: str | Path | None) -> None:
+        """Queue a force_calibration.json path for the acquisition thread."""
+        with self._lock:
+            self._pending_calibration = str(path) if path is not None else None
+
+    def _consume_pending_calibration(self, sensor) -> None:
+        with self._lock:
+            path = self._pending_calibration
+            self._pending_calibration = None
+        if path is None or sensor is None:
+            return
+        if hasattr(sensor, "set_calibration"):
+            sensor.set_calibration(path)
+
     def _set_end_reason(self, reason: str) -> None:
         with self._lock:
             if self._end_reason is None:
@@ -384,6 +401,7 @@ class SdkAcquisitionWorker:
 
                 none_streak_start = None
                 try:
+                    self._consume_pending_calibration(self._sensor)
                     self._sensor.compute_deformation(decompose=True, check_motion=False)
                     self._sensor.compute_contact()
                 except Exception:

shared/src/orisys_app_shared/force/calibration_io.py

@@ -1,28 +1,28 @@
-"""Build and write schema_version-2 force_calibration.json files."""
+"""Build and write schema_version-2 force_calibration.json files.
+
+Delegates schema/parse/write to ``orisys.calibration`` so the app and SDK share
+one format. ``CalSessionStore`` remains the UI sampling table.
+"""
 
 from __future__ import annotations
 
-import json
 from copy import deepcopy
 from dataclasses import asdict, dataclass, field
-from datetime import datetime, timezone
+from datetime import datetime
 from pathlib import Path
-from typing import Any, Iterable, Literal
+from typing import Any, Literal
+
+from orisys.calibration import (
+    CalSample as SdkCalSample,
+    build as sdk_build,
+    check as sdk_check,
+    pipeline_from_sensor_json,
+    write as sdk_write,
+)
 
 ChannelKey = Literal["fn", "fx", "fy"]
 CHANNEL_KEYS: tuple[ChannelKey, ...] = ("fn", "fx", "fy")
 
-_CHANNEL_TO_JSON = {
-    "fn": "normal",
-    "fx": "shear_x",
-    "fy": "shear_y",
-}
-_JSON_RAW_KEY = {
-    "normal": "fnormal",
-    "shear_x": "fshearx",
-    "shear_y": "fsheary",
-}
-
 WEIGHT_EPS = 1e-6
 
 
@@ -33,6 +33,14 @@ class CalSample:
     n: int
     std: float = 0.0
 
+    def to_sdk(self) -> SdkCalSample:
+        return SdkCalSample(
+            weight_n=float(self.weight_n),
+            raw_mean=float(self.raw_mean),
+            n=int(self.n),
+            std=float(self.std),
+        )
+
 
 @dataclass
 class CalSessionStore:
@@ -78,65 +86,22 @@ class CalSessionStore:
             out[key] = [asdict(s) for s in self.channel(key)]
         return out
 
+    def to_sdk_samples(self) -> dict[str, list[SdkCalSample]]:
+        return {
+            key: [s.to_sdk() for s in self.channel(key)]
+            for key in CHANNEL_KEYS
+        }
+
 
 def meta_from_sensor_json(path: str | Path | None) -> dict[str, Any]:
     """Pull stitch / tracker fields from a sensor.json for export meta."""
-    meta: dict[str, Any] = {
-        "stitch_resolution": None,
-        "dis_mode": None,
-        "hhd_downsample": None,
-        "config_ref": None,
+    pipeline = pipeline_from_sensor_json(path)
+    return {
+        "stitch_resolution": pipeline.get("stitch_resolution"),
+        "dis_mode": pipeline.get("dis_mode"),
+        "hhd_downsample": pipeline.get("hhd_downsample"),
+        "config_ref": pipeline.get("config_ref"),
     }
-    if path is None:
-        return meta
-    p = Path(path)
-    meta["config_ref"] = str(p)
-    if not p.is_file():
-        return meta
-    try:
-        data = json.loads(p.read_text(encoding="utf-8"))
-    except Exception:
-        return meta
-    if not isinstance(data, dict):
-        return meta
-    camera = data.get("camera") if isinstance(data.get("camera"), dict) else {}
-    tracker = data.get("tracker") if isinstance(data.get("tracker"), dict) else {}
-    stitch = camera.get("resolution_stitch")
-    if isinstance(stitch, (list, tuple)) and len(stitch) >= 2:
-        meta["stitch_resolution"] = [int(stitch[0]), int(stitch[1])]
-    if "dis_mode" in tracker:
-        try:
-            meta["dis_mode"] = int(tracker["dis_mode"])
-        except (TypeError, ValueError):
-            meta["dis_mode"] = tracker.get("dis_mode")
-    if "hhd_downsample" in tracker:
-        try:
-            meta["hhd_downsample"] = int(tracker["hhd_downsample"])
-        except (TypeError, ValueError):
-            meta["hhd_downsample"] = tracker.get("hhd_downsample")
-    return meta
-
-
-def _piecewise_channel(
-    *,
-    json_name: str,
-    samples: Iterable[CalSample],
-    signed: bool,
-) -> dict[str, Any] | None:
-    rows = sorted(samples, key=lambda s: abs(float(s.raw_mean)))
-    if len(rows) < 2:
-        return None
-    points = [[abs(float(s.raw_mean)), float(s.weight_n)] for s in rows]
-    block: dict[str, Any] = {
-        "method": "piecewise_linear",
-        "raw_key": _JSON_RAW_KEY[json_name],
-        "extrapolate": True,
-        "clamp_output_min": 0.0,
-        "points": points,
-    }
-    if signed:
-        block["signed"] = True
-    return block
 
 
 def build_force_calibration_v2(
@@ -145,64 +110,66 @@ def build_force_calibration_v2(
     meta: dict[str, Any] | None = None,
 ) -> tuple[dict[str, Any], list[str]]:
     """Build schema v2 JSON. Returns (document, skipped_channel_warnings)."""
-    warnings: list[str] = []
-    channels: dict[str, Any] = {}
-    for key, json_name in _CHANNEL_TO_JSON.items():
-        signed = key in ("fx", "fy")
-        block = _piecewise_channel(
-            json_name=json_name,
-            samples=store.channel(key),
-            signed=signed,
+    meta = dict(meta or {})
+    identity = {
+        "sensor_type": meta.get("sensor_type", ""),
+        "sn": meta.get("sn", ""),
+    }
+    pipeline = {
+        "stitch_resolution": meta.get("stitch_resolution"),
+        "dis_mode": meta.get("dis_mode"),
+        "hhd_downsample": meta.get("hhd_downsample"),
+        "config_ref": meta.get("config_ref"),
+    }
+    extra = {
+        k: v
+        for k, v in meta.items()
+        if k
+        not in (
+            "sensor_type",
+            "sn",
+            "stitch_resolution",
+            "dis_mode",
+            "hhd_downsample",
+            "config_ref",
+            "samples",
         )
-        if block is None:
-            if store.channel(key):
-                warnings.append(
-                    f"{key}: need at least 2 points (have {len(store.channel(key))})"
+    }
+    try:
+        cal = sdk_build(
+            store.to_sdk_samples(),
+            identity=identity,
+            pipeline=pipeline,
+            origin=str(meta.get("origin") or "user"),
+            extra_meta=extra,
         )
+    except Exception as exc:
+        # Match previous API: raise ValueError with channel warnings when empty.
+        raise ValueError(str(exc)) from exc
+
+    result = sdk_check(cal)
+    warnings = list(result.warnings)
+    for key in CHANNEL_KEYS:
+        if not cal.has(key):
+            rows = store.channel(key)
+            if rows:
+                msg = f"{key}: need at least 2 points (have {len(rows)})"
             else:
-                warnings.append(f"{key}: no samples")
-            continue
-        channels[json_name] = block
-
-    base_meta = {
-        "date": datetime.now(timezone.utc).astimezone().isoformat(timespec="seconds"),
-        "sensor_type": "",
-        "sn": "",
-        "stitch_resolution": None,
-        "dis_mode": None,
-        "hhd_downsample": None,
-        "record_duration_s": None,
-        "config_ref": None,
-        "samples": store.to_audit_dict(),
-    }
-    if meta:
-        for k, v in meta.items():
-            if k == "samples":
-                continue
-            base_meta[k] = v
-        if "samples" in meta and meta["samples"] is not None:
-            base_meta["samples"] = meta["samples"]
-
-    doc = {
-        "schema_version": 2,
-        "unit": "N",
-        "channels": channels,
-        "meta": base_meta,
-    }
-    return doc, warnings
+                msg = f"{key}: no samples"
+            if msg not in warnings:
+                warnings.append(msg)
+    return cal.to_dict(), warnings
 
 
 def write_force_calibration(
     doc: dict[str, Any],
     path: str | Path,
 ) -> Path:
-    path = Path(path)
-    path.parent.mkdir(parents=True, exist_ok=True)
-    path.write_text(
-        json.dumps(doc, indent=2, ensure_ascii=False) + "\n",
-        encoding="utf-8",
-    )
-    return path.resolve()
+    """Write a calibration dict (already built) to disk."""
+    from orisys.calibration import parse
+
+    cal = parse(doc)
+    return sdk_write(cal, path, overwrite=True)
 
 
 def export_force_calibration_v2(

shared/src/orisys_app_shared/force/history.py

@@ -1,12 +1,20 @@
-"""Rolling force history with optional display low-pass."""
+"""Rolling force history with optional display low-pass.
+
+Uses a time-windowed buffer (keep samples in ``[t_end - window_sec, t_end]``)
+with a headroom cap so high FPS still covers the visible X range after scroll.
+"""
 
 from __future__ import annotations
 
+import math
 from dataclasses import dataclass
 from typing import Optional
 
 import numpy as np
 
+DEFAULT_MAX_FPS = 90.0
+HEADROOM = 1.5
+
 
 @dataclass
 class PlotState:
@@ -41,8 +49,8 @@ def lowpass_filter(
         return y.copy()
 
 
-def _npoints_for_window(window_sec: float, sample_rate_hz: float) -> int:
-    return max(2, int(round(float(window_sec) * float(sample_rate_hz))))
+def _max_points_for_window(window_sec: float, max_fps: float) -> int:
+    return max(2, int(math.ceil(float(window_sec) * float(max_fps) * HEADROOM)))
 
 
 class MetricHistory:
@@ -55,35 +63,79 @@ class MetricHistory:
         sample_rate_hz: float | None = None,
         lowpass_cutoff_hz: float = 0.0,
         y_axis_min_span: float = 0.5,
+        max_fps: float = DEFAULT_MAX_FPS,
     ):
         self.channels = int(channels)
         self.window_sec = float(window_sec)
+        self.max_fps = max(1.0, float(max_fps))
         self.sample_rate_hz = (
-            float(sample_rate_hz)
-            if sample_rate_hz is not None
-            else (30.0 if self.window_sec <= 0 else 30.0)
+            float(sample_rate_hz) if sample_rate_hz is not None else 30.0
         )
+        # ``npoints`` overrides max capacity (tests / callers); else headroom cap.
         if npoints is None:
-            self.npoints = _npoints_for_window(self.window_sec, self.sample_rate_hz)
+            self.max_points = _max_points_for_window(self.window_sec, self.max_fps)
         else:
-            self.npoints = int(npoints)
+            self.max_points = max(2, int(npoints))
+        # Back-compat alias used by older callers.
+        self.npoints = self.max_points
         self.lowpass_cutoff_hz = float(lowpass_cutoff_hz)
         self.y_axis_min_span = float(y_axis_min_span)
+        self._capacity = self.max_points
         self.reset()
 
     def set_window_sec(self, window_sec: float) -> None:
         self.window_sec = max(0.1, float(window_sec))
-        self.npoints = _npoints_for_window(self.window_sec, self.sample_rate_hz)
-        self.reset()
+        self.max_points = _max_points_for_window(self.window_sec, self.max_fps)
+        self.npoints = self.max_points
+        self._ensure_capacity(self.max_points)
+        self._prune()
+        self._y_range_smooth = [None for _ in range(self.channels)]
 
     def reset(self) -> None:
-        self._data = np.full((self.npoints, 1 + self.channels), np.nan, dtype=np.float64)
+        self._capacity = max(self.max_points, 2)
+        self._data = np.full(
+            (self._capacity, 1 + self.channels), np.nan, dtype=np.float64
+        )
         self.sample_count = 0
         self._t0: Optional[float] = None
         self._y_range_smooth: list[Optional[tuple[float, float]]] = [
             None for _ in range(self.channels)
         ]
 
+    def _ensure_capacity(self, needed: int) -> None:
+        needed = max(needed, self.max_points, 2)
+        if needed <= self._capacity:
+            return
+        new_cap = max(needed, self._capacity * 2)
+        new_data = np.full(
+            (new_cap, 1 + self.channels), np.nan, dtype=np.float64
+        )
+        if self.sample_count > 0:
+            new_data[: self.sample_count] = self._data[: self.sample_count]
+        self._data = new_data
+        self._capacity = new_cap
+
+    def _prune(self) -> None:
+        """Drop samples older than the time window, then enforce max_points."""
+        n = self.sample_count
+        if n == 0:
+            return
+        t_end = float(self._data[n - 1, 0])
+        cutoff = t_end - self.window_sec
+        times = self._data[:n, 0]
+        # First index with t >= cutoff
+        keep_from = int(np.searchsorted(times, cutoff, side="left"))
+        if keep_from > 0:
+            remaining = n - keep_from
+            self._data[:remaining] = self._data[keep_from:n]
+            self.sample_count = remaining
+            n = remaining
+        if n > self.max_points:
+            drop = n - self.max_points
+            remaining = n - drop
+            self._data[:remaining] = self._data[drop:n]
+            self.sample_count = remaining
+
     def push(self, timestamp: float, *values: float) -> None:
         if len(values) != self.channels:
             raise ValueError(f"Expected {self.channels} values, got {len(values)}")
@@ -91,12 +143,11 @@ class MetricHistory:
             self._t0 = float(timestamp)
         t = float(timestamp) - self._t0
         row = (t, *map(float, values))
-        if self.sample_count < self.npoints:
+        if self.sample_count >= self._capacity:
+            self._ensure_capacity(self.sample_count + 1)
         self._data[self.sample_count, :] = row
         self.sample_count += 1
-            return
-        self._data[:-1, :] = self._data[1:, :]
-        self._data[-1, :] = row
+        self._prune()
 
     def _smooth_y_range(self, channel: int, ymin: float, ymax: float) -> tuple[float, float]:
         if self._y_range_smooth[channel] is None:
@@ -122,6 +173,24 @@ class MetricHistory:
         block = self._data[:n]
         times = block[:, 0].copy()
         values = block[:, 1:].copy()
+        t_end = float(times[-1])
+        if t_end >= self.window_sec:
+            x_range = (t_end - self.window_sec, t_end)
+            # Keep setData lean: only points inside the visible window.
+            mask = times >= x_range[0]
+            times = times[mask]
+            values = values[mask]
+            # Discrete samples usually start slightly after the left edge;
+            # prepend a hold point so the curve spans the full X range.
+            if times.size > 0 and float(times[0]) > x_range[0]:
+                times = np.concatenate(([x_range[0]], times))
+                values = np.vstack([values[0:1], values])
+        else:
+            x_range = (0.0, self.window_sec)
+
+        if times.size == 0:
+            return None
+
         if self.lowpass_cutoff_hz > 0:
             for i in range(self.channels):
                 values[:, i] = lowpass_filter(
@@ -129,11 +198,6 @@ class MetricHistory:
                     self.lowpass_cutoff_hz,
                     sample_rate_hz=self.sample_rate_hz,
                 )
-        t_end = float(times[-1])
-        if t_end >= self.window_sec:
-            x_range = (t_end - self.window_sec, t_end)
-        else:
-            x_range = (0.0, self.window_sec)
         y_ranges = []
         for i in range(self.channels):
             col = values[:, i]

shared/tests/test_force_history.py

@@ -0,0 +1,63 @@
+"""Tests for time-windowed MetricHistory (force plot buffer)."""
+
+from __future__ import annotations
+
+import pytest
+
+from orisys_app_shared.force.history import MetricHistory
+
+
+def _push_at_rate(hist: MetricHistory, *, fps: float, duration_sec: float, t0: float = 1000.0) -> None:
+    dt = 1.0 / fps
+    n = int(round(duration_sec * fps)) + 1
+    for i in range(n):
+        hist.push(t0 + i * dt, 1.0, 0.0, -1.0)
+
+
+def test_fill_phase_x_range_is_fixed_window():
+    hist = MetricHistory(window_sec=4.0, sample_rate_hz=30.0, lowpass_cutoff_hz=0.0, max_fps=90.0)
+    _push_at_rate(hist, fps=30.0, duration_sec=2.0)
+    state = hist.state()
+    assert state is not None
+    assert state.x_range == pytest.approx((0.0, 4.0))
+    assert float(state.times[-1]) < 4.0
+
+
+def test_high_fps_after_scroll_covers_x_range():
+    window = 4.0
+    hist = MetricHistory(window_sec=window, sample_rate_hz=30.0, lowpass_cutoff_hz=0.0, max_fps=90.0)
+    _push_at_rate(hist, fps=60.0, duration_sec=window + 1.0)
+    state = hist.state()
+    assert state is not None
+    x0, x1 = state.x_range
+    assert x1 - x0 == pytest.approx(window)
+    assert float(state.times[0]) == pytest.approx(x0)
+    assert float(state.times[-1]) == pytest.approx(x1)
+
+
+def test_nominal_30hz_after_scroll_covers_x_range():
+    window = 4.0
+    hist = MetricHistory(window_sec=window, sample_rate_hz=30.0, lowpass_cutoff_hz=0.0, max_fps=90.0)
+    _push_at_rate(hist, fps=30.0, duration_sec=window + 2.0)
+    state = hist.state()
+    assert state is not None
+    x0, x1 = state.x_range
+    assert x1 - x0 == pytest.approx(window)
+    assert float(state.times[0]) == pytest.approx(x0)
+
+
+def test_set_window_sec_prunes_older_samples():
+    hist = MetricHistory(window_sec=4.0, sample_rate_hz=30.0, lowpass_cutoff_hz=0.0, max_fps=90.0)
+    _push_at_rate(hist, fps=30.0, duration_sec=5.0)
+    before = hist.state()
+    assert before is not None
+    assert float(before.times[-1]) >= 4.0
+
+    hist.set_window_sec(1.0)
+    after = hist.state()
+    assert after is not None
+    assert after.x_range[1] - after.x_range[0] == pytest.approx(1.0)
+    assert float(after.times[0]) == pytest.approx(after.x_range[0])
+    # All retained samples must lie within the new window ending at t_end.
+    t_end = float(after.times[-1])
+    assert float(after.times[0]) >= t_end - 1.0 - 1e-9