传感器位置校准

apps/autocal/config/locales/en_US.json

@@ -52,7 +52,7 @@
     "stop": "Stop",
     "stop_hint": "Stop every axis now (the same command as 全部停止 in the strip).",
     "return_initial": "Return to zero",
-    "return_hint": "Yaw, pitch, table X/Y and press axis Z return to zero together.",
+    "return_hint": "Yaw, pitch and press axis Z return to 0. The table parks at its initial position: X at -1.0 mm, Y 15.0 mm forward.",
     "confirm_title": "Confirm motion",
     "confirm_execute": "Will move these axes together:\n\n{steps}\n\nCheck this against the machine before continuing.",
     "confirm_return": "Will move these axes back to zero together:\n\n{steps}",
@@ -405,10 +405,10 @@
     "row_residual": "Alignment residual",
     "row_frames": "Frame mapping",
     "tool_xy": "Tool X / Y",
-    "tool_hint": "Where the tool is in the table frame. With Y at 3 mm, every point's table Y is the solved move plus 3 mm, so the sensor shell tail stays on the platform centre axis.",
+    "tool_hint": "Where the tool is in the table frame. Each point's table move is measured from this position.",
     "sensor_xy": "Sensor X / Y",
     "sensor_zy": "Sensor Z / yaw",
-    "setup_hint": "How the sensor actually sits on the stack with the machine at zero: X/Y/Z translation and a yaw about Z. Z is the mounting plate, shims included — there is no separate plate field. Measure it on the real setup.",
+    "setup_hint": "How the sensor actually sits on the stack with the machine at zero: X/Y/Z translation and a yaw about Z. Z is the mounting-plate thickness. The plate on this bench is 8 mm.",
     "clear_points": "Clear points",
     "remove_selected": "Remove selected",
     "move_up": "Move up",

apps/autocal/config/locales/zh_CN.json

@@ -52,7 +52,7 @@
     "stop": "停止",
     "stop_hint": "立即停止所有轴（与顶栏「全部停止」相同）。",
     "return_initial": "回初始位",
-    "return_hint": "回转、俯仰、工作台 X/Y、压轴 Z 一起回到零点。",
+    "return_hint": "回转、俯仰、压轴 Z 回到 0。工作台停在初始位置：X 为 -1.0 mm，Y 为向前 15.0 mm。",
     "confirm_title": "确认运动",
     "confirm_execute": "将同时移动：\n\n{steps}\n\n请确认仿真与机床一致。",
     "confirm_return": "将同时移回零点：\n\n{steps}\n\n请确认机床上没有干涉。",
@@ -405,10 +405,10 @@
     "row_residual": "对齐残差",
     "row_frames": "坐标映射",
     "tool_xy": "刀具 X / Y",
-    "tool_hint": "刀具在工作台坐标系中的位置。Y 为 3 mm 时，每个测点的工作台 Y 都会在解算结果上再加 3 mm，使传感器壳体尾部与平台原中心同轴。",
+    "tool_hint": "刀具在工作台坐标系中的位置。每个测点的工作台移动都相对这个位置计算。",
     "sensor_xy": "传感器 X / Y",
     "sensor_zy": "传感器 Z / yaw",
-    "setup_hint": "传感器在转台零位时相对工作台原点的实际安装位姿：X/Y/Z 平移与绕 Z 的偏摆。Z 即安装板厚度（含垫片），无需另填。请按实际安装测量填写。",
+    "setup_hint": "传感器在转台零位时相对工作台原点的实际安装位姿：X/Y/Z 平移与绕 Z 的偏摆。Z 为安装板厚度，当前安装台是 8 mm。",
     "clear_points": "清空标定点",
     "remove_selected": "删除所选",
     "move_up": "上移",

apps/autocal/src/orisys_autocal/motion/pose_move.py

@@ -148,11 +148,16 @@ def plan_pose_move(
     return MovePlan(steps=tuple(steps), title=title, held=tuple(hold), together=together)
 
 
-def plan_return_to_initial(service: MotionService) -> MovePlan:
-    """Yaw, pitch, table X/Y and the press axis back to zero together."""
+def plan_return_to_initial(
+    service: MotionService, *, x_mm: float = 0.0, y_mm: float = 0.0
+) -> MovePlan:
+    """Yaw, pitch and the press axis back to zero. Table X/Y park at ``x_mm`` and ``y_mm``."""
+    targets = {role: 0.0 for role in ALIGN_ORDER}
+    targets["x"] = float(x_mm)
+    targets["y"] = float(y_mm)
     return plan_pose_move(
         service,
-        {role: 0.0 for role in ALIGN_ORDER},
+        targets,
         order=ALIGN_ORDER,
         together=True,
     )

apps/autocal/src/orisys_autocal/motion/service.py

@@ -64,16 +64,16 @@ AXIS_ROLES: tuple[str, ...] = ("x", "y", "z", "yaw", "pitch")
 LINEAR_ROLES: tuple[str, ...] = ("x", "y", "z")
 ROTARY_ROLES: tuple[str, ...] = ("yaw", "pitch")
 
-#: Default mapping, from the bench: drives 0-4 are x, y, pitch, yaw, z.
+#: Default mapping, from the bench: drives 0-4 are x, y, yaw, pitch, z.
 #:
-#: Deliberately *not* the same as the model's own order. It is written the way the
-#: machine is wired, so reading it against the terminal strip is a check rather than
-#: a translation.
+#: Pitch and yaw were first wired the other way around. Jogging the machine
+#: showed drive 2 is yaw (回转) and drive 3 is pitch (俯仰). The degree scales
+#: stay on the drive numbers in ``units.py``.
 DEFAULT_AXIS_ROLES: dict[str, int] = {
     "x": 0,
     "y": 1,
-    "pitch": 2,
-    "yaw": 3,
+    "pitch": 3,
+    "yaw": 2,
     "z": 4,
 }
 
@@ -905,10 +905,11 @@ class MotionService:
                 ),
             )
         try:
+            sent = float(value)
             if absolute:
-                self._transport.move_abs(axis, float(value))
+                self._transport.move_abs(axis, sent)
             else:
-                self._transport.move_rel(axis, float(value))
+                self._transport.move_rel(axis, sent)
         except (ZAuxError, OSError) as exc:
             code = getattr(exc, "code", 0)
             return self._logged(

apps/autocal/src/orisys_autocal/preferences.py

@@ -99,11 +99,10 @@ def _default_safety_limits() -> dict[str, float]:
         #: How far the axis may descend looking for contact before the run is
         #: aborted (workflow P7, no-contact abort).
         "contact_search_mm": 3.0,
-        #: Stage envelope, from the confirmed bench values: the yaw stage turns a
-        #: half-turn either way, the pitch stage a full turn. These are the limits a
-        #: pose move is checked against before any axis is commanded.
+        #: Stage envelope. Yaw turns ±180. Pitch is limited to ±90 on this bench:
+        #: past that the fixture interferes, so a pose move is refused.
         "max_yaw_deg": 180.0,
-        "max_pitch_deg": 360.0,
+        "max_pitch_deg": 90.0,
     }
 
 
@@ -220,21 +219,20 @@ def default_preferences() -> dict[str, Any]:
         #: x/y/z translation along the table's axes and a yaw about its z. **The z
         #: is the mounting plate**, so the plate is not a setting of its own — it
         #: lifts the sensing face and does nothing else, and two fields for one
-        #: number drift apart.
-        "finger_sensor_offset_mm": [0.0, 0.0, 0.0],
+        #: number drift apart. The bench plate under the finger is 8 mm thick.
+        "finger_sensor_offset_mm": [0.0, 0.0, 8.0],
         "finger_sensor_yaw_deg": 0.0,
-        #: Where the tool is, in the table frame, mm. Straight above the table
-        #: origin unless the real machine says otherwise; every XY move is measured
-        #: against it, so it is what makes the reported move match the bench. A tool
-        #: tip offset belongs here — it used to be a separate field, and having two
-        #: of them is what let the picture and the numbers disagree.
+        #: Where the tool is, in the table frame, mm. A tool-tip offset belongs
+        #: here. The bench X shift is the initial position, not this number.
         "finger_tool_xy_mm": [0.0, 3.0],
-        #: Stage travel, degrees. Confirmed at the bench: the vertical stage turns
-        #: a full half-turn either way (±180), and the horizontal stage turns
-        #: continuously. An earlier value of 90 was wrong and made half the patch
-        #: look unreachable when it is not.
+        #: Where 「回初始位」 parks the table, mm. X is 1 mm toward the negative
+        #: direction. Y is 15.0 mm forward of the old zero.
+        "table_initial_x_mm": -1.0,
+        "table_initial_y_mm": 15.0,
+        #: Stage travel, degrees. Yaw turns ±180. Pitch is held to ±90 because the
+        #: fixture interferes outside that.
         "finger_yaw_limit_deg": 180.0,
-        "finger_pitch_limit_deg": 360.0,
+        "finger_pitch_limit_deg": 90.0,
     }
 
 
@@ -277,6 +275,10 @@ def load_preferences() -> dict[str, Any]:
         offset.append(0.0)
     if plate and not offset[2]:
         offset[2] = plate
+    # A session started before the plate was entered saves Z as 0 and would put
+    # that 0 back over the 8 mm bench plate. Keep a stored non-zero thickness.
+    if not offset[2]:
+        offset[2] = float(defaults["finger_sensor_offset_mm"][2])
     prefs["finger_sensor_offset_mm"] = offset
 
     # The tool tip offset used to be a vector added to the reported coordinates
@@ -299,6 +301,27 @@ def load_preferences() -> dict[str, Any]:
             if value and not tool[index]:
                 tool[index] = value
     prefs["finger_tool_xy_mm"] = tool
+    # Closing AutoCal writes the whole in-memory file back. A session that started
+    # on the previous initial position would otherwise put that old Y over this one.
+    prefs["table_initial_x_mm"] = defaults["table_initial_x_mm"]
+    prefs["table_initial_y_mm"] = defaults["table_initial_y_mm"]
+    # 360° was the old pitch envelope. This fixture interferes outside ±90, and a
+    # session started on 360 would write that envelope back on close.
+    limits = prefs.get("safety_limits")
+    if isinstance(limits, dict):
+        try:
+            if float(limits.get("max_pitch_deg")) == 360.0:
+                limits["max_pitch_deg"] = 90.0
+        except (TypeError, ValueError):
+            limits["max_pitch_deg"] = 90.0
+    try:
+        if float(prefs.get("finger_pitch_limit_deg")) == 360.0:
+            prefs["finger_pitch_limit_deg"] = 90.0
+    except (TypeError, ValueError):
+        prefs["finger_pitch_limit_deg"] = 90.0
+    # Yaw travel is ±180. The same-sign pitch solution sits near ±150° of yaw,
+    # and a stored ±90 drops it, leaving the opposite pitch sign on one side.
+    prefs["finger_yaw_limit_deg"] = float(defaults["finger_yaw_limit_deg"])
     # A hand-edited task number must not reach the controller as typed.
     prefs["bas_task"] = clamp_bas_task(prefs.get("bas_task"))
     prefs = _migrate_axis_roles(prefs)
@@ -333,6 +356,11 @@ def _migrate_axis_roles(prefs: dict[str, Any]) -> dict[str, Any]:
             merged[role] = int(value)
         except (TypeError, ValueError):
             continue
+    # The first bench note had these two drives swapped. A session that still
+    # has that pair would otherwise put it back on close.
+    if merged.get("pitch") == 2 and merged.get("yaw") == 3:
+        merged["pitch"] = 3
+        merged["yaw"] = 2
     prefs["axis_roles"] = merged
     return prefs
 

apps/autocal/src/orisys_autocal/ui/window.py

@@ -278,8 +278,8 @@ class AutoCalMainWindow(QMainWindow):
         # platform connected. Its stack carries the bench's stage travel limits,
         # because a pose outside them is not a pose.
         self.finger_stack = PlatformStack(
-            yaw_limit_deg=float(self.prefs.get("finger_yaw_limit_deg") or 90.0),
-            pitch_limit_deg=float(self.prefs.get("finger_pitch_limit_deg") or 360.0),
+            yaw_limit_deg=float(self.prefs.get("finger_yaw_limit_deg") or 180.0),
+            pitch_limit_deg=float(self.prefs.get("finger_pitch_limit_deg") or 90.0),
         )
         self.finger_panel = FingerPanel(
             self.finger_stack,
@@ -1104,8 +1104,19 @@ class AutoCalMainWindow(QMainWindow):
         )
 
     def _on_return_to_initial(self) -> None:
-        """Yaw, pitch, table X/Y and the press axis back to zero together."""
-        plan = plan_return_to_initial(self.poller.service)
+        """Yaw, pitch and Z back to zero. Table X/Y park at the stored initial."""
+
+        def initial(key: str) -> float:
+            try:
+                return float(self.prefs.get(key) or 0.0)
+            except (TypeError, ValueError):
+                return 0.0
+
+        plan = plan_return_to_initial(
+            self.poller.service,
+            x_mm=initial("table_initial_x_mm"),
+            y_mm=initial("table_initial_y_mm"),
+        )
         self._start_move(plan, t("move.return_initial"))
 
     def _start_move(self, plan, title: str, *, report=None) -> None:

apps/autocal/tests/test_pose_move.py

@@ -136,6 +136,31 @@ def test_returning_to_zero_moves_the_five_axes_together():
     assert all(step.target == 0.0 for step in plan.steps)
 
 
+def test_return_to_initial_can_park_y_forward():
+    service = make_service()
+    plan = plan_return_to_initial(service, x_mm=-1.0, y_mm=15.0)
+    targets = {step.role: step.target for step in plan.steps}
+    assert targets == {"yaw": 0.0, "pitch": 0.0, "x": -1.0, "y": 15.0, "z": 0.0}
+
+
+def test_pitch_positive_direction_matches_the_drive():
+    service = make_service()
+    pitch = ROLES["pitch"]
+    yaw = ROLES["yaw"]
+    seen: list[bool] = []
+    service.transport.jog = lambda axis, forward: seen.append((axis, forward))  # type: ignore[method-assign]
+
+    assert service.jog(pitch, True).ok
+    assert seen == [(pitch, True)]
+    assert service.move_rel(pitch, 90.0).ok
+    assert service.move_rel(yaw, 90.0).ok
+    assert service.transport.get_dpos(pitch) == pytest.approx(90.0)
+    assert service.transport.get_dpos(yaw) == pytest.approx(90.0)
+    snapshot = service.poll()
+    assert snapshot.axis(pitch).dpos == pytest.approx(90.0)
+    assert snapshot.axis(yaw).dpos == pytest.approx(90.0)
+
+
 # ----------------------------------------------------------------------- guards
 
 

shared/src/orisys_app_shared/record/experiment.py

@@ -77,6 +77,7 @@ FORCES_HEADER = (
     "FN_output_N",
     "FX_output_N",
     "FY_output_N",
+    "Fmag_raw",
 )
 FRAMES_HEADER = (
     "frame_id",
@@ -109,6 +110,14 @@ ROW_BACKLOG = 8192
 VIDEO_PACING_TOLERANCE = 0.5
 
 
+def raw_magnitude(fn: float, fx: float, fy: float) -> float:
+    """Magnitude of the three raw force components. Missing any one leaves it blank."""
+    values = (fn, fx, fy)
+    if not all(np.isfinite(value) for value in values):
+        return float("nan")
+    return float(np.sqrt(sum(value * value for value in values)))
+
+
 def format_value(value: float) -> str:
     """Full-precision CSV cell. ``NaN`` means "not available" and is left empty.
 
@@ -1142,6 +1151,7 @@ class _SessionWriter:
                 format_value(sample.fn_n_processed),
                 format_value(sample.fx_n_processed),
                 format_value(sample.fy_n_processed),
+                format_value(raw_magnitude(sample.fn_raw, sample.fx_raw, sample.fy_raw)),
             )
         )
 

shared/tests/test_experiment_recorder.py

@@ -118,11 +118,15 @@ def test_unavailable_values_are_empty_not_zero(root):
 
     failed = rows[1]
     assert failed["valid"] == "0"
-    for column in ("FN_raw", "FX_raw", "FY_raw", "FN_N", "FX_N", "FY_N"):
+    for column in ("FN_raw", "FX_raw", "FY_raw", "FN_N", "FX_N", "FY_N", "Fmag_raw"):
         assert failed[column] == "", "a failed readout was written as a number"
 
+    recorded = rows[0]
+    assert recorded["Fmag_raw"] == repr((9.0 ** 2 + 0.4 ** 2 + 0.4 ** 2) ** 0.5)
+
     no_raw = rows[2]
     assert no_raw["FN_raw"] == "" and no_raw["FX_raw"] == "", "raw was not left empty"
+    assert no_raw["Fmag_raw"] == ""
     assert no_raw["FN_N"] == "2.0", "calibrated values must still be recorded"
     assert no_raw["valid"] == "1"