fixed calibration data not loading due to path

sensors/box/force_calibration.json

@@ -1,5 +1,5 @@
 {
-  "schema_version": 1,
+  "schema_version": 2,
   "unit": "N",
   "channels": {
     "normal": {
@@ -14,8 +14,22 @@
         [62000.0, 2.377]
       ]
     },
-    "shear": {
+    "shear_x": {
       "method": "piecewise_linear",
+      "raw_key": "fshearx",
+      "input": "components",
+      "signed": true,
+      "extrapolate": true,
+      "clamp_output_min": 0.0,
+      "points": [
+        [1000.0, 0.0],
+        [36000.0, 1.19],
+        [68000.0, 2.06]
+      ]
+    },
+    "shear_y": {
+      "method": "piecewise_linear",
+      "raw_key": "fsheary",
       "input": "components",
       "signed": true,
       "extrapolate": true,

src/orisys/configs.py

@@ -1,5 +1,6 @@
 import json
 import shutil
+import sys
 from contextlib import ExitStack
 from dataclasses import dataclass
 from importlib.resources import as_file, files
@@ -25,29 +26,116 @@ def _resource_path(*parts: str) -> Path | None:
         return None
 
 
-def _candidate_config_dirs() -> list[Path]:
+def _unique_paths(paths) -> list[Path]:
-    """
+    """Ordered, de-duplicated paths (Windows comparison is case-insensitive)."""
-    Candidate config directories for editable installs and packaged wheels.
-    """
-    here = Path(__file__).resolve().parent
-    candidates = [
-        here / "configs",                    # packaged wheel layout: orisys/configs/*.json
-        here.parent.parent / "config",       # editable install from repo: repo_root/config/*.json
-        here.parent / "config",              # fallback
-        Path.cwd() / "config",               # script launched from repo root
-    ]
-
     unique: list[Path] = []
-    for path in candidates:
+    seen: set[str] = set()
-        if path not in unique:
+    for path in paths:
+        try:
+            key = str(path.resolve()).casefold()
+        except OSError:  # pragma: no cover - defensive: unresolvable path
+            key = str(path).casefold()
+        if key in seen:
+            continue
+        seen.add(key)
         unique.append(path)
     return unique
 
 
-def _candidate_sensor_roots() -> list[Path]:
+def _is_sdk_runtime_root(path: Path) -> bool:
-    """Candidate roots that contain per-sensor bundle folders."""
+    """Whether ``path`` carries the runnable SDK layout.
+
+    The anchor is the **folder layout**, never the folder's name: a distribution
+    folder may be called anything (a release checkout, a renamed copy, an
+    unpacked zip), but it always ships ``examples/`` beside ``sensors/``. That is
+    what distinguishes a run root from an arbitrary directory, and it is why a
+    renamed root keeps working while ``dist/**`` (``sensors/`` without
+    ``examples/``) is not mistaken for one.
+    """
+    try:
+        if not path.is_dir():
+            return False
+        return (path / "examples").is_dir() and (path / "sensors").is_dir()
+    except OSError:  # pragma: no cover - defensive: unreadable path
+        return False
+
+
+def _runtime_roots() -> list[Path]:
+    """Runnable SDK roots for this process, nearest to the launcher first.
+
+    Evaluated once at import time, so a process that changes directory later
+    keeps the answer it started with.
+    """
+    anchors: list[Path] = []
+
+    def add(path: Path) -> None:
+        if path not in anchors:
+            anchors.append(path)
+
+    cwd = Path.cwd()
+    add(cwd)
+
+    # A script run from a subdirectory (``<root>/examples/foo.py``, or a caller
+    # that launched from ``<root>/scripts``) still names its root through argv[0].
+    script_dir: Path | None = None
+    try:
+        argv0 = sys.argv[0] if sys.argv else ""
+        if argv0:
+            candidate = Path(argv0).expanduser()
+            script_dir = candidate.resolve().parent if candidate.is_file() else None
+    except (OSError, ValueError):  # pragma: no cover - defensive
+        script_dir = None
+
+    # Walk up from both, so the root is found however deep the launcher sits.
+    for start in (cwd, script_dir):
+        if start is None:
+            continue
+        for candidate in (start, *start.parents):
+            add(candidate)
+
+    # Roots that put themselves on sys.path (``python <root>/examples/foo.py``
+    # with the root as cwd, ``PYTHONPATH=<root>``, and similar).
+    for entry in list(sys.path):
+        if not entry:
+            continue
+        try:
+            add(Path(entry).expanduser())
+        except (OSError, ValueError):  # pragma: no cover - defensive
+            continue
+
+    return [path for path in _unique_paths(anchors) if _is_sdk_runtime_root(path)]
+
+
+def _candidate_config_dirs() -> list[Path]:
+    """Candidate config directories, the running SDK root first.
+
+    A run root's ``config/`` outranks the packaged copy so a bundle's
+    ``sensor.json`` and its ``force_calibration.json`` come from the same place.
+    """
     here = Path(__file__).resolve().parent
-    candidates = []
+    return _unique_paths([
+        *(root / "config" for root in _runtime_roots()),
+        here / "configs",                    # packaged wheel layout: orisys/configs/*.json
+        here.parent.parent / "config",       # editable install from repo: repo_root/config/*.json
+        here.parent / "config",              # fallback
+        Path.cwd() / "config",               # script launched from repo root
+    ])
+
+
+def _candidate_sensor_roots() -> list[Path]:
+    """Candidate roots that contain per-sensor bundle folders.
+
+    Lookup order:
+
+    1. the ``sensors/`` of every runnable SDK root found at startup, nearest
+       first -- so the bundle under the directory that is actually running wins,
+       whatever that directory is called;
+    2. the packaged resource ``orisys/sensors`` (wheel installs);
+    3. the module-relative candidates (editable checkout, packaged tree);
+    4. the current working directory, last, as a safety net.
+    """
+    here = Path(__file__).resolve().parent
+    candidates = [root / "sensors" for root in _runtime_roots()]
     packaged = _resource_path("sensors")
     if packaged is not None:
         candidates.append(packaged)          # packaged wheel layout: orisys/sensors/
@@ -57,11 +145,7 @@ def _candidate_sensor_roots() -> list[Path]:
         here.parent / "sensors",
         Path.cwd() / "sensors",
     ])
-    unique: list[Path] = []
+    return _unique_paths(candidates)
-    for path in candidates:
-        if path not in unique:
-            unique.append(path)
-    return unique
 
 
 def _get_config_dir() -> Path:
@@ -130,6 +214,44 @@ def resolve_sensor_bundle(name: str) -> SensorBundle | None:
     return None
 
 
+def describe_bundle_resolution(name: str) -> dict:
+    """Explain how ``name`` resolved, so a missing calibration stops being silent.
+
+    A bundle can resolve and still carry no ``force_calibration.json``: the
+    lookup stops at the first root that has ``<name>/sensor.json`` and never
+    asks whether that root also has the coefficients. Reporting which bundle was
+    found -- and which roots were passed over -- is what makes that case
+    distinguishable from "no bundle at all", which is otherwise what the caller
+    sees.
+
+    Returns ``name``, the ``searched`` roots in order, and the first root that
+    supplied ``<name>/sensor.json`` together with whether it carried a
+    ``force_calibration.json``.
+    """
+    requested = CONFIG_ALIASES.get(str(name), str(name))
+    searched = _candidate_sensor_roots()
+    for root in searched:
+        sensor_json = root / requested / "sensor.json"
+        if not sensor_json.is_file():
+            continue
+        return {
+            "name": requested,
+            "searched": searched,
+            "found_root": sensor_json.parent,
+            "sensor_json": sensor_json,
+            "force_calibration_json": (
+                sensor_json.parent / "force_calibration.json"
+            ).is_file(),
+        }
+    return {
+        "name": requested,
+        "searched": searched,
+        "found_root": None,
+        "sensor_json": None,
+        "force_calibration_json": False,
+    }
+
+
 def resolve_sensor_config_path(name: str) -> Path | None:
     """Return ``sensor.json`` for a resolved sensor bundle."""
     bundle = resolve_sensor_bundle(name)

src/orisys/sensor.py

@@ -217,6 +217,9 @@ class Sensor:
         self._force_raw = (0.0, 0.0, 0.0)
         self.calibration: Optional[cal_mod.Calibration] = None
         self._force_cal_sensor_name: Optional[str] = None
+        #: Why no calibration was applied, when a bundle existed but carried no
+        #: usable coefficients. ``None`` means the question never came up.
+        self._force_cal_attempts: Optional[list[dict]] = None
         self._init_force_calibration()
 
         # ---------------------------------------------------------------
@@ -330,10 +333,11 @@ class Sensor:
         if self.verbose:
             if self.calibration is not None and self.calibration.source_path is not None:
                 print(f"Force calibration: {self.calibration.source_path}")
-            elif self._force_cal_sensor_name:
+            elif self._force_cal_attempts is not None:
-                print(
+                # A bundle was resolved for this sensor type, so "file missing"
-                    f"Force calibration: sensors/{self._force_cal_sensor_name}/force_calibration.json"
+                # would be the wrong story: name the bundle and the roots that
-                )
+                # were searched instead.
+                print(self._force_calibration_note())
             else:
                 print("Force calibration: raw (no force_calibration.json)")
 
@@ -1258,22 +1262,71 @@ class Sensor:
                 ordered.append(name)
         return ordered
 
+    def _force_calibration_note(self) -> str:
+        """Explain a bundle that resolved but carried no usable coefficients.
+
+        The old message ("raw (no force_calibration.json)") reads as "the file is
+        missing", which is exactly the wrong story when the lookup found a
+        bundle from another root and stopped there without ever asking whether
+        that root had coefficients.
+        """
+        attempts = self._force_cal_attempts or []
+        found = [entry for entry in attempts if entry.get("found_root") is not None]
+        with_cal = [entry for entry in found if entry.get("force_calibration_json")]
+        chosen = (with_cal or found or attempts or [None])[0]
+        searched: list = []
+        for entry in attempts:
+            for root in entry.get("searched") or ():
+                if root not in searched:
+                    searched.append(root)
+        lines: list[str] = []
+        if chosen is None:
+            lines.append("Force calibration: raw (no sensor bundle resolved)")
+        else:
+            root = chosen["found_root"]
+            if chosen.get("force_calibration_json"):
+                lines.append(
+                    f"Force calibration: raw (a bundle was found at {root}, but its "
+                    "force_calibration.json could not be loaded)"
+                )
+            else:
+                lines.append(
+                    f"Force calibration: raw (bundle found at {root} has no "
+                    "force_calibration.json)"
+                )
+        if searched:
+            lines.append(
+                "  roots searched: " + "; ".join(str(root) for root in searched)
+            )
+        return "\n".join(lines)
+
     def _init_force_calibration(self) -> None:
         """Load force calibration from ``cal_path`` or the product bundle."""
         self.calibration = None
         self._force_cal_sensor_name = None
+        self._force_cal_attempts = None
 
         if self.cal_path is not None and str(self.cal_path).strip():
             # Explicit path: missing/invalid raises (no silent fallback).
             self.calibration = cal_mod.load(self.cal_path, strict=True)
             return
 
+        attempts: list[dict] = []
         for name in self._bundle_name_candidates():
             cal = cal_mod.load(sensor_type=name)
             if cal is not None:
                 self.calibration = cal
                 self._force_cal_sensor_name = name
+                self._force_cal_attempts = None
                 return
+            try:
+                attempts.append(configs.describe_bundle_resolution(name))
+            except Exception:  # noqa: BLE001 - diagnostics must never break loading
+                continue
+        # Deliberately NOT setting ``_force_cal_sensor_name``: callers read a
+        # non-None value there as "this sensor is calibrated", and a bundle
+        # without coefficients is not that.
+        self._force_cal_attempts = attempts or None
 
     @property
     def force_calibrated(self) -> bool:
@@ -1292,11 +1345,14 @@ class Sensor:
         if cal is None:
             self.calibration = None
             self._force_cal_sensor_name = None
+            self._force_cal_attempts = None
             return
         if isinstance(cal, cal_mod.Calibration):
             self.calibration = cal
+            self._force_cal_attempts = None
             return
         self.calibration = cal_mod.load(cal, strict=True)
+        self._force_cal_attempts = None
 
     def _apply_force_filter(self):
         pre_filter = np.asarray(self._force_raw, dtype=np.float64)

tests/test_calibration.py

@@ -243,8 +243,84 @@ def test_missing_cal_path_raises():
 
 def test_parse_shipped_box_file_directly():
     cal = parse(json.loads(_box_cal_path().read_text(encoding="utf-8")), source_path=_box_cal_path())
-    assert cal.schema_version == 1
+    assert cal.schema_version == 2
     assert cal.convert(10000.0, 36000.0, -36000.0) == pytest.approx((0.377, 1.19, -1.19))
+    # The shipped file names both shear axes outright: no shared block, no clone.
+    assert set(cal.channels) == {"fn", "fx", "fy"}
+    fx, fy = cal.get("FX"), cal.get("FY")
+    assert fx is not None and fy is not None and fx is not fy
+    for curve in (fx, fy):
+        assert curve.signed is True
+        assert curve.extrapolate is True
+        assert curve.clamp_output_min == pytest.approx(0.0)
+        assert len(curve.points) == 3
+    assert fx.raw_key == "fshearx"
+    assert fy.raw_key == "fsheary"
+
+
+def test_the_shipped_box_shear_axes_can_drift_apart(tmp_path: Path):
+    """The whole point of the split: FX and FY are independent curves.
+
+    A document with the same shape as the shipped one but different per-axis
+    points must apply each axis's own curve. Re-collapsing the axes into one
+    shared ``shear`` block makes this fail.
+    """
+    doc = {
+        "schema_version": 2,
+        "unit": "N",
+        "channels": {
+            "normal": {
+                "method": "piecewise_linear",
+                "points": [[0.0, 0.0], [1000.0, 1.0]],
+            },
+            "shear_x": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "input": "components",
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+                "points": [[0.0, 0.0], [500.0, 2.0]],
+            },
+            "shear_y": {
+                "method": "piecewise_linear",
+                "signed": True,
+                "input": "components",
+                "extrapolate": True,
+                "clamp_output_min": 0.0,
+                "points": [[0.0, 0.0], [500.0, 3.0]],
+            },
+        },
+    }
+    path = tmp_path / "split.json"
+    path.write_text(json.dumps(doc), encoding="utf-8")
+    cal = load(path)
+    assert cal is not None
+    assert cal.convert(0.0, 500.0, 500.0)[1:] == pytest.approx((2.0, 3.0))
+    assert cal.convert(0.0, -500.0, 500.0)[1:] == pytest.approx((-2.0, 3.0))
+
+
+def test_out_of_range_readings_extend_instead_of_being_dropped():
+    """Outside the calibrated range the nearest segment is extended.
+
+    This pins the "extend, never ignore, never reuse a previous coefficient"
+    behaviour of the shipped box file, so flipping ``extrapolate`` has to be a
+    deliberate edit that fails this test first.
+    """
+    cal = load(sensor_type="box")
+    assert cal is not None
+    fx, fy, fn = cal.get("FX"), cal.get("FY"), cal.get("FN")
+    assert fx is not None and fy is not None and fn is not None
+    # 136000 = 2 x the top raw break (68000 -> 2.06): the last segment's slope is
+    # applied again, so the value keeps growing past the calibrated range.
+    (r0, n0), (r1, n1) = fx.points[-2], fx.points[-1]
+    extended = n1 + (n1 - n0) / (r1 - r0) * (136000.0 - r1)
+    assert extended > n1
+    assert fx.convert_component(136000.0) == pytest.approx(extended)
+    assert fy.convert_component(136000.0) == pytest.approx(extended)
+    # A negative beyond the range keeps its sign.
+    assert fx.convert_component(-136000.0) == pytest.approx(-extended)
+    # Below the first point the normal channel floors at clamp_output_min.
+    assert fn.convert(500.0) == pytest.approx(0.0)
 
 
 # ------------------------------------------------------- filter fingerprint

tests/test_signal_processing.py

@@ -2,11 +2,13 @@
 
 from __future__ import annotations
 
+import json
+
 import numpy as np
 import pytest
 from scipy.signal import butter, filtfilt
 
-from orisys import Sensor
+from orisys import Sensor, configs
 from orisys.signal_processing import (
     NORMAL_FORCE_CAL_OFFSET,
     NORMAL_FORCE_CAL_SLOPE,
@@ -263,3 +265,156 @@ def test_configure_hhd_downsample_invalidates_solver_cache():
             sensor.configure(hhd_downsample="nope")
     finally:
         sensor.disconnect()
+
+
+# ------------------------------------------------- bundle resolution anchors
+#
+# The bundle is chosen by the *running* root's folder layout, not by the root's
+# name and not by whichever checkout happens to be importable. These build small
+# real trees, because ``_runtime_roots`` asks the filesystem whether a directory
+# carries ``examples/`` beside ``sensors/``.
+_CAL_DOC = {
+    "schema_version": 2,
+    "unit": "N",
+    "channels": {
+        "normal": {"method": "piecewise_linear", "points": [[0.0, 0.0], [1000.0, 1.0]]},
+        "shear_x": {
+            "method": "piecewise_linear",
+            "signed": True,
+            "points": [[0.0, 0.0], [500.0, 2.0]],
+        },
+        "shear_y": {
+            "method": "piecewise_linear",
+            "signed": True,
+            "points": [[0.0, 0.0], [500.0, 3.0]],
+        },
+    },
+}
+
+
+def _make_root(base, *, name="anything", sensor_json=True, calibration=True):
+    """A runnable SDK root: ``examples/`` beside ``sensors/<name>/``."""
+    root = base / name
+    (root / "examples").mkdir(parents=True, exist_ok=True)
+    if sensor_json:
+        (root / "examples" / "basic_pipeline.py").write_text("# demo\n", encoding="utf-8")
+    bundle = root / "sensors" / "mini"
+    bundle.mkdir(parents=True, exist_ok=True)
+    if sensor_json:
+        (bundle / "sensor.json").write_text(
+            json.dumps({"name": "prototype"}), encoding="utf-8"
+        )
+    if calibration:
+        (bundle / "force_calibration.json").write_text(
+            json.dumps(_CAL_DOC), encoding="utf-8"
+        )
+    return root
+
+
+def test_runtime_root_anchor_keys_on_layout_not_on_the_folder_name(tmp_path):
+    named = _make_root(tmp_path, name="some-random-name")
+    assert configs._is_sdk_runtime_root(named) is True
+
+    no_examples = tmp_path / "dist-like"
+    (no_examples / "sensors" / "mini").mkdir(parents=True)
+    assert configs._is_sdk_runtime_root(no_examples) is False
+
+    neither = tmp_path / "plain"
+    neither.mkdir()
+    assert configs._is_sdk_runtime_root(neither) is False
+
+
+def test_runtime_roots_walk_up_from_a_subdirectory(tmp_path, monkeypatch):
+    root = _make_root(tmp_path, name="renamed-release")
+    subdir = root / "examples"
+    monkeypatch.setattr(configs.Path, "cwd", classmethod(lambda cls: subdir))
+    roots = [str(path) for path in configs._runtime_roots()]
+    assert str(root) in roots
+
+
+def test_the_running_root_bundle_beats_a_calibration_less_checkout(
+    tmp_path, monkeypatch
+):
+    """The reported bug: a nearer bundle without coefficients must not win."""
+    running = _make_root(tmp_path, name="running-root")
+    checkout = _make_root(tmp_path, name="importable-checkout", calibration=False)
+    monkeypatch.setattr(configs, "_runtime_roots", lambda: [running, checkout])
+
+    bundle = configs.resolve_sensor_bundle("mini")
+    assert bundle is not None
+    assert bundle.root == (running / "sensors" / "mini").resolve()
+    assert bundle.force_calibration_json == (
+        running / "sensors" / "mini" / "force_calibration.json"
+    ).resolve()
+
+    # The whole point: the running root's document is the one that reaches the
+    # sensor, split shear and all.
+    sensor = Sensor("external", config_name="mini", verbose=False, backend="cpu")
+    try:
+        assert sensor.force_calibrated is True
+        assert sensor.force_unit == "N"
+        assert sensor.calibration.source_path == (
+            running / "sensors" / "mini" / "force_calibration.json"
+        ).resolve()
+    finally:
+        sensor.disconnect()
+
+
+def test_a_nearer_bundle_wins_even_without_coefficients(tmp_path, monkeypatch):
+    """Nearest bundle wins, so a calibration-less nearer one hides a farther one.
+
+    That is the chosen precedence (the running root is authoritative), and the
+    diagnostic exists precisely so this stops being silent: this is the shape of
+    the original report, where a checkout's ``mini`` has only ``sensor.json``.
+    """
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    running = _make_root(tmp_path, name="run-root")
+    monkeypatch.setattr(configs, "_runtime_roots", lambda: [checkout, running])
+    bundle = configs.resolve_sensor_bundle("mini")
+    assert bundle is not None
+    assert bundle.root == (checkout / "sensors" / "mini").resolve()
+    assert bundle.force_calibration_json is None
+    info = configs.describe_bundle_resolution("mini")
+    assert info["found_root"] == (checkout / "sensors" / "mini").resolve()
+    assert info["force_calibration_json"] is False
+
+
+def test_describe_bundle_resolution_names_the_bundle_and_the_searched_roots(
+    tmp_path, monkeypatch
+):
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    running = _make_root(tmp_path, name="run-root")
+    roots = [checkout / "sensors", running / "sensors"]
+    # Patched at the root list, so no real bundle on this machine can satisfy
+    # the lookup while the "nothing found" case is being asserted.
+    monkeypatch.setattr(configs, "_candidate_sensor_roots", lambda: list(roots))
+
+    info = configs.describe_bundle_resolution("mini")
+    assert info["found_root"] == (checkout / "sensors" / "mini").resolve()
+    assert info["force_calibration_json"] is False
+    assert [str(path) for path in info["searched"]] == [str(p) for p in roots]
+
+    (checkout / "sensors" / "mini" / "sensor.json").unlink()
+    (running / "sensors" / "mini" / "sensor.json").unlink()
+    missing = configs.describe_bundle_resolution("mini")
+    assert missing["found_root"] is None
+    assert missing["sensor_json"] is None
+    assert missing["force_calibration_json"] is False
+
+
+def test_the_calibration_note_names_the_bundle_that_was_found(
+    tmp_path, monkeypatch
+):
+    checkout = _make_root(tmp_path, name="checkout", calibration=False)
+    monkeypatch.setattr(configs, "_runtime_roots", lambda: [checkout])
+    sensor = Sensor("external", config_name="mini", verbose=False, backend="cpu")
+    try:
+        assert sensor.calibration is None
+        # Still None: callers read a non-None value here as "calibrated".
+        assert sensor._force_cal_sensor_name is None
+        note = sensor._force_calibration_note()
+        assert "has no force_calibration.json" in note
+        assert str((checkout / "sensors" / "mini").resolve()) in note
+        assert "roots searched" in note
+    finally:
+        sensor.disconnect()