ros_contorl/thirdparty/flexiv_rdk/test/test_endurance.cpp

/**
 * @test test_endurance.cpp
 * Endurance test running Cartesian impedance control to slowly sine-sweep near home for a duration
 * of user-specified hours. Raw data will be logged to CSV files continuously.
 * @copyright Copyright (C) 2016-2026 Flexiv Ltd. All Rights Reserved.
 * @author Flexiv
 */

#include <flexiv/rdk/robot.hpp>
#include <flexiv/rdk/scheduler.hpp>
#include <flexiv/rdk/utility.hpp>
#include <spdlog/spdlog.h>

#include <iostream>
#include <fstream>
#include <string>
#include <cmath>
#include <thread>
#include <atomic>

using namespace flexiv;

namespace {
/** RT loop period [sec] */
const double kLoopPeriod = 0.001;

/** TCP sine-sweep amplitude [m] */
const double kSwingAmp = 0.1;

/** TCP sine-sweep frequency [Hz] */
const double kSwingFreq = 0.025; // = 10mm/s linear velocity

/** Current Cartesian-space pose (position + rotation) of robot TCP */
std::map<rdk::JointGroup, std::array<double, rdk::kPoseSize>> g_curr_tcp_pose;

/** Test duration converted from user-specified hours to loop counts */
uint64_t g_test_duration_loop_counts = 0;

/** Time duration for each log file [loop counts] */
const unsigned int kLogDurationLoopCounts = 10 * 60 * 1000; // = 10 min/file

/** Data to be logged in low-priority thread */
struct LogData
{
    std::map<rdk::JointGroup, std::array<double, rdk::kPoseSize>> tcp_pose;
    std::map<rdk::JointGroup, std::array<double, rdk::kCartDoF>> tcp_force;
} g_log_data;

/** Atomic signal to stop the test */
std::atomic<bool> g_stop = {false};
}

void HighPriorityTask(rdk::Robot& robot,
    const std::map<rdk::JointGroup, std::string>& single_arm_groups,
    const std::map<rdk::JointGroup, std::array<double, rdk::kPoseSize>>& all_init_poses)
{
    // Local periodic loop counter
    static uint64_t loop_counter = 0;

    try {
        // Monitor fault on the connected robot
        if (robot.fault()) {
            throw std::runtime_error(
                "HighPriorityTask: Fault occurred on the connected robot, exiting ...");
        }

        // Swing along Z direction
        std::map<rdk::JointGroup, rdk::RtCartesianCmd> rt_cmds;
        for (const auto& [group, _] : single_arm_groups) {
            auto target_pose = g_curr_tcp_pose.at(group);
            target_pose[2] = all_init_poses.at(group)[2]
                             + kSwingAmp * sin(2 * M_PI * kSwingFreq * loop_counter * kLoopPeriod);
            g_curr_tcp_pose[group] = target_pose;
            rt_cmds[group] = rdk::RtCartesianCmd(target_pose);
        }
        robot.StreamCartesianMotionForce(rt_cmds);

        // Save data to global buffer, not using mutex to avoid interruption on RT loop from
        // potential priority inversion
        for (const auto& [group, states] : robot.states()) {
            g_log_data.tcp_pose[group] = states.tcp_pose;
            g_log_data.tcp_force[group] = states.tcp_wrench;
        }

        // Stop after test duration has elapsed
        if (++loop_counter > g_test_duration_loop_counts) {
            g_stop = true;
        }

    } catch (const std::exception& e) {
        spdlog::error(e.what());
        g_stop = true;
    }
}

void LowPriorityTask()
{
    // Low-priority task loop counter
    uint64_t loop_counter = 0;

    // Data logging CSV file
    std::ofstream csv_file;

    // CSV file name
    std::string csv_file_name;

    // CSV file counter (data during the test is divided to multiple files)
    unsigned int file_counter = 0;

    // Wait for a while for the robot states data to be available
    std::this_thread::sleep_for(std::chrono::seconds(2));

    // Use while loop to prevent this thread from return
    while (true) {
        // Log data at 1kHz
        std::this_thread::sleep_for(std::chrono::milliseconds(1));
        loop_counter++;

        // Close existing log file and create a new one periodically
        if (loop_counter % kLogDurationLoopCounts == 0) {
            if (csv_file.is_open()) {
                csv_file.close();
                spdlog::info("Saved log file: {}", csv_file_name);
            }

            // Increment log file counter
            file_counter++;

            // Create new file name using the updated counter as suffix
            csv_file_name = "endurance_test_data_" + std::to_string(file_counter) + ".csv";

            // Open new log file
            csv_file.open(csv_file_name);
            if (csv_file.is_open()) {
                spdlog::info("Created new log file: {}", csv_file_name);
            } else {
                spdlog::error("Failed to create log file: {}", csv_file_name);
            }
        }

        // Log data to file in CSV format
        if (csv_file.is_open()) {
            // Loop counter x1, then grouped TCP pose x7 and TCP wrench x6
            csv_file << loop_counter << ",";
            for (const auto& [group, pose] : g_log_data.tcp_pose) {
                csv_file << rdk::kJointGroupNames.at(group) << ",";
                for (const auto& i : pose) {
                    csv_file << i << ",";
                }
                for (const auto& i : g_log_data.tcp_force.at(group)) {
                    csv_file << i << ",";
                }
            }
            // End of line
            csv_file << '\n';
        }

        // Check if the test duration has elapsed
        if (g_stop) {
            spdlog::info("Test duration has elapsed, saving any open log file ...");
            // Close log file
            if (csv_file.is_open()) {
                csv_file.close();
                spdlog::info("Saved log file: {}", csv_file_name);
            }
            // Exit thread
            return;
        }
    }
}

void PrintHelp()
{
    // clang-format off
    std::cout << "Required arguments: [robot_sn] [test_hours]" << std::endl;
    std::cout << "    robot_sn: Serial number of the robot to connect. Remove any space, e.g. Enlight-L-123456" << std::endl;
    std::cout << "    test_hours: Duration of the test, can have decimals" << std::endl;
    std::cout << "Optional arguments: None" << std::endl;
    std::cout << std::endl;
    // clang-format on
}

int main(int argc, char* argv[])
{
    // Parse Parameters
    //==============================================================================================
    if (argc < 3 || rdk::utility::ProgramArgsExistAny(argc, argv, {"-h", "--help"})) {
        PrintHelp();
        return 1;
    }

    // Serial number of the robot to connect to
    std::string robot_sn = argv[1];

    // test duration in hours
    double test_hours = std::stof(argv[2]);
    // convert duration in hours to loop counts
    g_test_duration_loop_counts = (uint64_t)(test_hours * 3600.0 * 1000.0);
    spdlog::info("Test duration: {} hours = {} cycles", test_hours, g_test_duration_loop_counts);

    try {
        // RDK Initialization
        //==========================================================================================
        // Instantiate robot interface
        rdk::Robot robot(robot_sn);

        // Clear fault on the connected robot if any
        if (robot.fault()) {
            spdlog::warn("Fault occurred on the connected robot, trying to clear ...");
            // Try to clear the fault
            if (!robot.ClearFault()) {
                spdlog::error("Fault cannot be cleared, exiting ...");
                return 1;
            }
            spdlog::info("Fault on the connected robot is cleared");
        }

        // Servo on the robot, make sure the E-stop is released
        spdlog::info("Servo on the robot ...");
        robot.ServoOn();

        // Wait for the robot to become operational
        while (!robot.operational()) {
            std::this_thread::sleep_for(std::chrono::seconds(1));
        }
        spdlog::info("Robot is now operational");

        // Move robot to home pose
        //==========================================================================================
        // Direct Cartesian control can only be executed by single-arm joint groups
        const auto& single_arm_groups = robot.info().single_arm_groups;
        if (single_arm_groups.empty()) {
            throw std::runtime_error("No single-arm joint group found on the connected robot");
        }

        robot.Home();

        // Switch mode after robot is at home
        robot.SwitchMode(rdk::Mode::RT_CARTESIAN_MOTION_FORCE);

        for (const auto& [group, _] : single_arm_groups) {
            robot.SetForceControlAxis(
                group, std::array<bool, rdk::kCartDoF> {false, false, false, false, false, false});
        }

        // Set initial pose to current TCP pose
        std::map<rdk::JointGroup, std::array<double, rdk::kPoseSize>> all_init_pose;
        const auto robot_states = robot.states();
        for (const auto& [group, _] : single_arm_groups) {
            all_init_pose[group] = robot_states.at(group).tcp_pose;
            g_curr_tcp_pose[group] = robot_states.at(group).tcp_pose;
            spdlog::info("[{}] Initial TCP pose set to [position 3x1, rotation (quaternion) 4x1]: {}",
                rdk::kJointGroupNames.at(group), rdk::utility::Arr2Str(all_init_pose.at(group)));
        }

        // Periodic Tasks
        //==========================================================================================
        rdk::Scheduler scheduler;
        // Add periodic task with 1ms interval and highest applicable priority
        scheduler.AddTask(std::bind(HighPriorityTask, std::ref(robot), std::cref(single_arm_groups),
                              std::cref(all_init_pose)),
            "HP periodic", 1, scheduler.max_priority());
        // Start all added tasks
        scheduler.Start();

        // Use std::thread for logging task without strict chronology
        std::thread low_priority_thread(LowPriorityTask);

        // low_priority_thread is responsible to release blocking
        low_priority_thread.join();

    } catch (const std::exception& e) {
        spdlog::error(e.what());
        return 1;
    }

    return 0;
}