diff --git a/.github/workflows/tests.yml b/.github/workflows/tests.yml index 7a06f83..2e3b064 100644 --- a/.github/workflows/tests.yml +++ b/.github/workflows/tests.yml @@ -36,21 +36,67 @@ jobs: fi - name: Run pre-commit uses: pre-commit/action@v3.0.1 + test: name: ${{ matrix.os }} / Python ${{ matrix.python-version }} runs-on: ${{ matrix.os }} - timeout-minutes: 30 + timeout-minutes: 45 strategy: fail-fast: false matrix: os: [ubuntu-latest, windows-latest, macos-latest] python-version: ['3.11', '3.12', '3.13', '3.14'] + defaults: + run: + shell: bash -l {0} + steps: - name: Checkout repository (with submodules) uses: actions/checkout@v4 - - name: Setup Python + - name: Detect matching pinokin branch + id: pinokin + shell: bash + run: | + BRANCH="${GITHUB_HEAD_REF:-${GITHUB_REF_NAME}}" + if git ls-remote --heads https://github.com/Jepson2k/pinokin.git "$BRANCH" 2>/dev/null | grep -q .; then + echo "matching=true" >> "$GITHUB_OUTPUT" + echo "branch=$BRANCH" >> "$GITHUB_OUTPUT" + else + echo "matching=false" >> "$GITHUB_OUTPUT" + fi + + # ---------------------------------------------------------------------- + # Path A: matching pinokin branch -> conda env (provides libpinocchio + + # libcoal headers/libs) so pinokin can be built from source. We install + # PAROL6 first (which pulls in the pinned pinokin v0.1.6 wheel) and + # then override pinokin with the source-built wheel from the matching + # branch. This is the only way to exercise unreleased pinokin features + # before a release lands. + # ---------------------------------------------------------------------- + - name: Setup Miniforge (matching pinokin branch) + if: steps.pinokin.outputs.matching == 'true' + uses: conda-incubator/setup-miniconda@v3 + with: + miniforge-version: latest + python-version: ${{ matrix.python-version }} + conda-remove-defaults: true + activate-environment: parol6-test + + - name: Clone matching pinokin branch + if: steps.pinokin.outputs.matching == 'true' + run: | + git clone --depth=1 --branch="${{ steps.pinokin.outputs.branch }}" https://github.com/Jepson2k/pinokin.git pinokin-src + conda env update -n parol6-test -f pinokin-src/environment.yml + + # ---------------------------------------------------------------------- + # Path B: no matching pinokin branch -> plain pip with the pinned + # release wheel. Anything in PAROL6 that requires a newer pinokin + # feature will fail loudly here (intended). + # ---------------------------------------------------------------------- + - name: Setup Python (pinned pinokin) + if: steps.pinokin.outputs.matching != 'true' uses: actions/setup-python@v5 with: python-version: ${{ matrix.python-version }} @@ -58,7 +104,6 @@ jobs: cache-dependency-path: pyproject.toml - name: Install package - shell: bash run: | python -m pip install --upgrade pip pip install -e ".[dev]" pytest-timeout @@ -72,6 +117,16 @@ jobs: pip install --force-reinstall "waldoctl @ git+https://github.com/Jepson2k/waldoctl.git@${BRANCH}" fi + # Override the pinned pinokin v0.1.6 wheel with the matching-branch + # source build. --force-reinstall + --no-deps swaps just pinokin + # without disturbing other resolved dependencies. + - name: Override pinokin with matching-branch source build + if: steps.pinokin.outputs.matching == 'true' + run: | + cd pinokin-src + pip install . --no-build-isolation --force-reinstall --no-deps + python -c "from pinokin import CollisionChecker; print('CollisionChecker available')" + - name: Show environment run: | python -V diff --git a/parol6/PAROL6_ROBOT.py b/parol6/PAROL6_ROBOT.py index 28b1ede..1434c6c 100644 --- a/parol6/PAROL6_ROBOT.py +++ b/parol6/PAROL6_ROBOT.py @@ -2,13 +2,14 @@ import atexit import logging +import os from dataclasses import dataclass from pathlib import Path from typing import Final import numpy as np from numpy.typing import NDArray -from pinokin import Robot +from pinokin import CollisionChecker, Robot from parol6.tools import get_tool_transform @@ -56,10 +57,171 @@ _urdf_path = str( Path(__file__).resolve().parent / "urdf_model" / "urdf" / "PAROL6.urdf" ) +_mesh_dir = str(Path(_urdf_path).resolve().parent.parent) # Current robot instance (tool transform applied in-place) robot: Robot = Robot(_urdf_path) +# Self-collision checker bound to the same pinokin Robot. Built eagerly when +# ``parol6.config`` is imported (config.py calls ``_init_collision_checker``), +# i.e. on any ``import parol6``; stays None when collision checking is disabled +# or geometry fails to load. Treat None as "checks disabled" everywhere. +# TODO: defer construction to a server-side ``ensure_collision_checker()`` so +# pure RobotClient script subprocesses don't pay the URDF-rewrite + BVH build. +collision: CollisionChecker | None = None + + +def _resolved_urdf_for_collision() -> str: + """Return a path to a URDF with `package://parol6/...` rewritten to + absolute `file://` paths so pinokin's mesh loader can resolve them. + + The PAROL6 URDF was authored for a ROS package layout (meshes at + `parol6/meshes/`) but the Python package places them at + `parol6/urdf_model/meshes/`. Rewriting at runtime keeps the source + URDF unchanged and avoids fragile symlink farms. + + Writes a fresh temp file each call and cleans it up at interpreter exit. + """ + import tempfile + + src = Path(_urdf_path) + text = src.read_text() + mesh_root = Path(_mesh_dir) / "meshes" + # `package://parol6/meshes/foo.STL` -> a plain absolute path coal/assimp can + # open. Use a POSIX-style path, NOT a `file://` URI: coal strips the scheme + # naively, which on Windows leaves an invalid `/D:/...` (leading slash before + # the drive letter). `as_posix()` gives `/abs/...` on POSIX and `D:/abs/...` + # on Windows — both openable directly. + rewritten = text.replace("package://parol6/meshes/", mesh_root.as_posix() + "/") + fd, tmp_path = tempfile.mkstemp(prefix="parol6_collision_", suffix=".urdf") + with os.fdopen(fd, "w") as f: + f.write(rewritten) + + @atexit.register + def _cleanup_tmp_urdf() -> None: + try: + os.unlink(tmp_path) + except OSError: + pass + + return tmp_path + + +def _init_collision_checker(enabled: bool, srdf_path: str) -> None: + """Build the singleton CollisionChecker when *enabled*. + + Config values are passed in (by ``parol6.config`` after its knobs are + defined) rather than imported here, keeping the dependency one-directional + — ``config`` imports ``PAROL6_ROBOT``, not the other way around. + """ + global collision + if not enabled: + collision = None + return + + try: + # All package:// mesh URIs are rewritten to absolute file:// paths in + # the temp URDF, so no package_dirs resolution is needed. + urdf_for_collision = _resolved_urdf_for_collision() + c = CollisionChecker(robot, urdf_for_collision) + if srdf_path and os.path.exists(srdf_path): + c.load_srdf(srdf_path) + collision = c + logger.info( + "Collision checker loaded: %d pairs, %d geometry objects", + c.num_collision_pairs, + c.num_geometry_objects, + ) + except Exception as e: # noqa: BLE001 + # Enabled but failed to build: fail loud. Silently running the arm with + # no collision checking is unsafe; require an explicit opt-out. + if os.getenv("PAROL6_ALLOW_NO_COLLISION"): + logger.warning( + "Collision checker init failed; continuing without it because " + "PAROL6_ALLOW_NO_COLLISION is set (UNSAFE): %s", + e, + ) + collision = None + return + raise RuntimeError( + "Collision checker failed to initialize. Fix the cause, or set " + "PAROL6_ALLOW_NO_COLLISION=1 to run without collision checking " + f"(UNSAFE). Original error: {e}" + ) from e + + +# Geometry-object names for meshes attached to the collision checker on +# behalf of the currently-active tool, plus the (tool, variant) they were +# attached for so an unchanged re-apply can skip the disk reload. +_active_tool_geom_names: list[str] = [] +_active_tool_geom_key: tuple[str, str | None] | None = None + + +def _refresh_collision_tool_geometry( + tool_key: str, + variant_key: str | None = None, +) -> None: + """Sync the global collision checker's tool geometry with the active + tool. No-op if the checker isn't built yet (so this is safe to call + during early module init, before the checker is ensured). + + Skips the work entirely when the (tool, variant) is unchanged: collision + mesh placement comes only from ``spec.origin``, never the TCP offset, so a + TCP-offset-only ``apply_tool`` would otherwise reload STLs and rebuild BVHs + on the control-loop thread for no change. + """ + global _active_tool_geom_key + if collision is None: + return + key = (tool_key, variant_key) + if key == _active_tool_geom_key: + return + # Clear the previous tool's geometry. Mark the key inconsistent until the + # new attaches finish, so a mid-loop failure self-repairs on the next call + # (otherwise the early-return above would skip a partial attach forever). + for name in _active_tool_geom_names: + collision.remove_geometry_by_name(name) + _active_tool_geom_names.clear() + _active_tool_geom_key = None + + from parol6.tools import get_registry + + cfg = None if tool_key == "NONE" else get_registry().get(tool_key) + if cfg is not None: + # A variant with non-empty meshes wholesale replaces cfg.meshes; an + # empty variant falls back to cfg.meshes (deliberately — unlike WC's + # swap_tool_mesh, which renders nothing for a mesh-less variant). + meshes = cfg.meshes + if variant_key: + for v in cfg.variants: + if v.key == variant_key and v.meshes: + meshes = v.meshes + break + mesh_root = Path(_mesh_dir) / "meshes" + try: + for spec in meshes: + path = mesh_root / spec.file + # All current MeshSpecs use rpy=(0,0,0); rotation is baked into + # the STL geometry (see _MESH_RPY comment in tools.py). Add a + # rotation branch here when a non-identity rpy appears. + T = np.eye(4, dtype=np.float64) + T[:3, 3] = spec.origin + collision.attach_mesh_to_frame( + spec.file, + str(path), + parent_frame="L6", + placement=T, + ) + _active_tool_geom_names.append(spec.file) + except Exception: + # Roll back a partial attach so the checker never holds half a tool. + for name in _active_tool_geom_names: + collision.remove_geometry_by_name(name) + _active_tool_geom_names.clear() + raise + + _active_tool_geom_key = key + def apply_tool( tool_name: str, @@ -95,6 +257,8 @@ def apply_tool( robot.clear_tool_transform() logger.info(f"Applied tool {label} (identity)") + _refresh_collision_tool_geometry(tool_name, variant_key=variant_key or None) + # Initialize with no tool apply_tool("NONE") diff --git a/parol6/commands/_collision_guard.py b/parol6/commands/_collision_guard.py new file mode 100644 index 0000000..08b01d0 --- /dev/null +++ b/parol6/commands/_collision_guard.py @@ -0,0 +1,110 @@ +"""Shared self-collision pre-flight check used by motion commands. + +`guard_joint_path(positions)` raises `TrajectoryPlanningError(SYS_SELF_COLLISION)` +if any sampled configuration along the interpolated joint path would self-collide +(or world-collide given runtime obstacles attached to the singleton checker). +It runs server-side during trajectory build, so it raises the planning-time +error type (like the other do_setup guards), not the client-side `MotionError`. +Disabled-by-config or unloaded-checker scenarios are no-ops. +""" + +from __future__ import annotations + +import numpy as np +from numpy.typing import NDArray + +import parol6.PAROL6_ROBOT as PAROL6_ROBOT +from parol6.config import COLLISION_PATH_SAMPLES +from parol6.utils.error_catalog import make_error +from parol6.utils.error_codes import ErrorCode +from parol6.utils.errors import TrajectoryPlanningError + +# Penetration-depth tolerance (metres) for the start-in-collision escape check: +# a move whose min-distance drops by no more than this counts as "not deeper", +# absorbing numerical jitter in the signed-distance query. +_ESCAPE_TOL = 1e-4 + + +def _format_pairs(pairs: list[tuple[str, str]]) -> str: + """Render colliding (name, name) pairs as a human-readable string. + + Caps at 4 to keep error messages tractable when many pairs collide + simultaneously (rare in practice; usually the first one is the + actionable one anyway). + """ + if not pairs: + return "?" + head = pairs[:4] + rendered = ", ".join(f"{a} vs {b}" for a, b in head) + if len(pairs) > 4: + rendered += f" (+{len(pairs) - 4} more)" + return rendered + + +def guard_joint_path(positions: NDArray[np.float64]) -> None: + """Raise if the path drives into collision. + + `positions` is (N, nq) joint positions in radians. Endpoints are always + included; up to COLLISION_PATH_SAMPLES interior samples are checked. + + Normally any collision along the path is rejected. The exception is when the + path *starts* already in collision (checker enabled at a colliding pose, or a + tool attach created an overlap): rejecting outright would trap the arm, so an + *escaping* move is permitted — one that adds no new colliding pair and goes no + deeper than the start. Driving into a new collision, or deeper into the + current one, still raises. + """ + checker = PAROL6_ROBOT.collision + if checker is None: + return + + # Load-bearing: normalize to a C-contiguous float64 array for the C++ bindings. + pos = np.ascontiguousarray(positions, dtype=np.float64) + n = pos.shape[0] + if n == 0: + return + + # Subsample at COLLISION_PATH_SAMPLES interior points. np.linspace includes + # both endpoints, and n > target guarantees spacing > 1 so the rounded + # indices are strictly increasing; np.unique stays as cheap insurance. + target = max(2, COLLISION_PATH_SAMPLES + 2) + if n <= target: + idx = None + sub = pos # already contiguous float64 — no copy needed + else: + idx = np.unique(np.linspace(0, n - 1, target).round().astype(int)) + sub = pos[idx] # fancy indexing yields a fresh contiguous float64 array + + def _raise(sample: int, pairs: list[tuple[str, str]]) -> None: + raise TrajectoryPlanningError( + make_error( + ErrorCode.SYS_SELF_COLLISION, + sample=str(sample), + total=str(n), + pairs=_format_pairs(pairs), + ) + ) + + hit = checker.check_path(sub) + if hit < 0: + return # entire path clear — the common case + if hit > 0: + # Start is clear but the path drives into a collision — reject it. + sample = hit if idx is None else int(idx[hit]) + _raise(sample, checker.colliding_pairs(pos[sample])) + + # hit == 0: already in collision at the start. Permit an escaping move — one + # that introduces no new colliding pair and goes no deeper than the start — + # so the arm isn't trapped. (A global min-distance trend alone can't tell an + # improving start-collision from a new shallower one, so we check pairs too.) + d0 = checker.min_distance(pos[0]) + start_pairs = set(checker.colliding_pairs(pos[0])) + for j in range(1, sub.shape[0]): + new_pairs = set(checker.colliding_pairs(sub[j])) - start_pairs + deeper = checker.min_distance(sub[j]) < d0 - _ESCAPE_TOL + if new_pairs or deeper: + sample = j if idx is None else int(idx[j]) + pairs = ( + sorted(new_pairs) if new_pairs else checker.colliding_pairs(pos[sample]) + ) + _raise(sample, pairs) diff --git a/parol6/commands/basic_commands.py b/parol6/commands/basic_commands.py index 59d0f52..768d6e9 100644 --- a/parol6/commands/basic_commands.py +++ b/parol6/commands/basic_commands.py @@ -29,6 +29,8 @@ from parol6.config import deg_to_steps from parol6.server.transports.transport_factory import is_simulation_mode +import parol6.PAROL6_ROBOT as PAROL6_ROBOT # noqa: N811 + from .base import ( ExecutionStatusCode, MotionCommand, @@ -187,6 +189,19 @@ def execute_step(self, state: "ControllerState") -> ExecutionStatusCode: se.set_jog_velocity(self._jog_vel_rad) pos_rad, _vel, _finished = se.tick() + + # Don't stream a self-colliding configuration. This only fires in the + # collision case (in_collision is False during normal jogging), so it + # never affects ordinary motion; an abrupt stop is acceptable when the + # alternative is driving the arm into itself. (The Cartesian jog uses a + # graceful CSE-based stop; JogJ has no equivalent smoother, so it halts.) + checker = PAROL6_ROBOT.collision + if checker is not None and checker.in_collision(pos_rad): + logger.warning("[JOGJ] self-collision predicted - stopping jog") + se.active = False + self.finish() + return ExecutionStatusCode.COMPLETED + self._q_rad_buf[:] = pos_rad rad_to_steps(self._q_rad_buf, self._steps_buf) self.set_move_position(state, self._steps_buf) diff --git a/parol6/commands/cartesian_commands.py b/parol6/commands/cartesian_commands.py index 54f4169..54fd3b8 100644 --- a/parol6/commands/cartesian_commands.py +++ b/parol6/commands/cartesian_commands.py @@ -9,6 +9,7 @@ import numpy as np import parol6.PAROL6_ROBOT as PAROL6_ROBOT +from parol6.commands._collision_guard import guard_joint_path from parol6.config import ( CART_ANG_JOG_MIN, CART_LIN_JOG_MIN, @@ -155,7 +156,11 @@ def execute_step(self, state: "ControllerState") -> ExecutionStatusCode: if not finished and self._dot_buf > 1e-8: ik_result = solve_ik(PAROL6_ROBOT.robot, smoothed_pose, self._q_ik_seed) if ik_result.success and ik_result.q is not None: - self._track_and_send(state, ik_result.q) + # Don't stream a self-colliding config during the release + # deceleration; skip the send and let the CSE finish stopping. + checker = PAROL6_ROBOT.collision + if checker is None or not checker.in_collision(ik_result.q): + self._track_and_send(state, ik_result.q) return ExecutionStatusCode.EXECUTING cse.active = False @@ -182,11 +187,18 @@ def execute_step(self, state: "ControllerState") -> ExecutionStatusCode: if self._vel_ratio > 1.0: velocity /= self._vel_ratio - # Set target velocity (WRF transforms to body frame, TRF uses body directly) - if self.p.frame == "WRF": - cse.set_jog_velocity_1dof_wrf(self._axis_index, velocity, self.is_rotation) - else: - cse.set_jog_velocity_1dof(self._axis_index, velocity, self.is_rotation) + # Set target velocity (WRF transforms to body frame, TRF uses body + # directly). While stopping (IK failure or predicted self-collision) + # leave the CSE target at zero so cse.stop()'s deceleration actually + # takes effect — re-commanding full velocity every tick would overwrite + # it and the arm would never decelerate (nor reach the vel<1e-6 exit). + if not self._ik_stopping: + if self.p.frame == "WRF": + cse.set_jog_velocity_1dof_wrf( + self._axis_index, velocity, self.is_rotation + ) + else: + cse.set_jog_velocity_1dof(self._axis_index, velocity, self.is_rotation) smoothed_pose, smoothed_vel, _finished = cse.tick() @@ -214,9 +226,25 @@ def execute_step(self, state: "ControllerState") -> ExecutionStatusCode: return ExecutionStatusCode.COMPLETED return ExecutionStatusCode.EXECUTING - # IK succeeded - if we were stopping, recover by resuming jogging + # Self-collision predicted at next streamed config? Mirror the + # IK-failure graceful-stop pathway: decelerate via cse.stop() rather + # than raising mid-jog. Operator regains control after smoothing. + if PAROL6_ROBOT.collision is not None and PAROL6_ROBOT.collision.in_collision( + ik_result.q + ): + if not self._ik_stopping: + _ik_warn( + logger, + "[CARTJOG] self-collision predicted - initiating stop", + ) + cse.stop() + self._ik_stopping = True + return ExecutionStatusCode.EXECUTING + + # Reachable + collision-free again — if we were stopping (IK failure or + # predicted self-collision), recover by resuming jogging. if self._ik_stopping: - logger.info("[CARTJOG] IK recovered - resuming jog") + logger.info("[CARTJOG] constraint cleared - resuming jog") steps_to_rad(state.Position_in, self._q_rad_buf) cse.sync_pose(get_fkine_se3(state)) self._q_commanded[:] = self._q_rad_buf @@ -285,6 +313,9 @@ def _precompute_trajectory(self, state: "ControllerState") -> None: stop_on_failure=stop_on_failure, ) + if not joint_path.is_partial: + guard_joint_path(joint_path.positions) + if joint_path.is_partial: ik_valid = joint_path.valid assert ik_valid is not None @@ -331,7 +362,7 @@ def _precompute_trajectory(self, state: "ControllerState") -> None: ) def _compute_target_pose(self, state: "ControllerState") -> None: - """Compute target pose — absolute or relative based on rel flag.""" + """Compute target pose - absolute or relative based on rel flag.""" pose = self.p.pose if self.p.rel: @@ -443,6 +474,8 @@ def do_setup_with_blend( self.do_setup(state) return 0 + guard_joint_path(joint_path.positions) + # Use minimum speed/accel across chain, sum durations when all duration-based min_speed = self.p.resolved_speed min_accel = self.p.accel diff --git a/parol6/commands/curved_commands.py b/parol6/commands/curved_commands.py index fd2daf2..ad65814 100644 --- a/parol6/commands/curved_commands.py +++ b/parol6/commands/curved_commands.py @@ -11,6 +11,7 @@ import numpy as np +from parol6.commands._collision_guard import guard_joint_path from parol6.commands.base import TrajectoryMoveCommandBase from parol6.config import INTERVAL_S, LIMITS, steps_to_rad from parol6.motion import CircularMotion, JointPath, SplineMotion, TrajectoryBuilder @@ -154,6 +155,8 @@ def do_setup(self, state: "ControllerState") -> None: ) ) + guard_joint_path(joint_path.positions) + builder = TrajectoryBuilder( joint_path=joint_path, profile=state.motion_profile, diff --git a/parol6/commands/joint_commands.py b/parol6/commands/joint_commands.py index 2894127..17f2cb6 100644 --- a/parol6/commands/joint_commands.py +++ b/parol6/commands/joint_commands.py @@ -16,6 +16,7 @@ import numpy as np import parol6.PAROL6_ROBOT as PAROL6_ROBOT +from parol6.commands._collision_guard import guard_joint_path from parol6.commands.base import TrajectoryMoveCommandBase from parol6.config import ( INTERVAL_S, @@ -86,6 +87,7 @@ def do_setup(self, state: ControllerState) -> None: current_rad = self._q_rad_buf joint_path = JointPath.interpolate(current_rad, target_rad, n_samples=50) + guard_joint_path(joint_path.positions) builder = TrajectoryBuilder( joint_path=joint_path, profile=state.motion_profile, @@ -194,6 +196,7 @@ def do_setup_with_blend( return 0 joint_path = JointPath(positions=positions) + guard_joint_path(joint_path.positions) # Use minimum speed/accel across chain, sum durations when all duration-based min_speed = self.p.resolved_speed diff --git a/parol6/config.py b/parol6/config.py index 476b9c6..9d3c61f 100644 --- a/parol6/config.py +++ b/parol6/config.py @@ -564,6 +564,34 @@ def _build_cart_kinodynamic( dtype=np.float64, ) +# ----------------------------------------------------------------------------- +# Self-collision checking (pinokin CollisionChecker) +# ----------------------------------------------------------------------------- +# Pre-flight collision checks reject motion commands whose interpolated +# joint path enters a self-colliding (or world-colliding) configuration. +# Disable via env: PAROL6_COLLISION_CHECK=0 +COLLISION_CHECK_ENABLED: bool = os.getenv( + "PAROL6_COLLISION_CHECK", "1" +).strip().lower() in ("1", "true", "yes", "on") + +# Number of interior joint-space samples checked along an interpolated path. +# Endpoints are always checked. 0 => endpoints only. +# At ~38 us p99 per check on the bundled simplified meshes (see the speed +# diagnostic), 16 samples is ~0.7 ms per command; world geometry attached at +# runtime may raise the per-check cost. +COLLISION_PATH_SAMPLES: int = int(os.getenv("PAROL6_COLLISION_PATH_SAMPLES", "16")) + +# Optional SRDF file with disabled-pair info. Defaults to the bundled +# parol6/urdf_model/srdf/PAROL6.srdf when present. +_default_srdf = Path(__file__).resolve().parent / "urdf_model" / "srdf" / "PAROL6.srdf" +COLLISION_SRDF_PATH: str = os.getenv( + "PAROL6_COLLISION_SRDF", + str(_default_srdf) if _default_srdf.exists() else "", +) + +# Populate PAROL6_ROBOT.collision now that the config knobs are defined. +PAROL6_ROBOT._init_collision_checker(COLLISION_CHECK_ENABLED, COLLISION_SRDF_PATH) + # ----------------------------------------------------------------------------- # Utility Functions diff --git a/parol6/robot.py b/parol6/robot.py index 6e3b9e3..f30e827 100644 --- a/parol6/robot.py +++ b/parol6/robot.py @@ -1,4 +1,4 @@ -"""Unified PAROL6 robot — lifecycle, configuration, kinematics, and factories. +"""Unified PAROL6 robot - lifecycle, configuration, kinematics, and factories. Inherits from ``waldoctl.Robot`` ABC. All parol6-specific details (subprocess management, pinokin, IK solver, etc.) @@ -489,7 +489,7 @@ def _resolve_mesh_dir() -> str: @dataclass class Parol6IKResult: - """IK result — structurally compatible with the web commander's IKResult Protocol.""" + """IK result - structurally compatible with the web commander's IKResult Protocol.""" q: NDArray[np.float64] # radians success: bool @@ -504,7 +504,7 @@ class Parol6IKResult: class Robot(_RobotABC): - """Unified PAROL6 robot — inherits from waldoctl.Robot ABC. + """Unified PAROL6 robot - inherits from waldoctl.Robot ABC. Combines identity, configuration, FK/IK kinematics, controller lifecycle, and client factories. Supports both sync and async context managers:: @@ -667,6 +667,11 @@ def set_active_tool( *tcp_offset_m*: optional (x, y, z) user offset in meters, composed on top of the tool's registered transform. *variant_key*: optional variant whose TCP overrides the tool default. + + Note: this mutates the per-instance pinokin Robot, not the global + `PAROL6_ROBOT.collision` scene. Server-side tool changes route + through `PAROL6_ROBOT.apply_tool`, which is where collision-mesh + attachment is wired. """ from parol6.tools import get_tool_transform @@ -769,6 +774,63 @@ def fk_batch(self, joint_path_rad: NDArray[np.float64]) -> NDArray[np.float64]: result[i, 5] = rpy[2] return result + def in_collision(self, q_rad: NDArray[np.float64]) -> bool: + """Return True iff `q_rad` is in self/world collision. False if disabled. + + Queries the process-global ``PAROL6_ROBOT.collision`` checker (shared by + all Robot methods here); its tool geometry reflects ``PAROL6_ROBOT + .apply_tool`` calls in this process (server / dry-run), not + :meth:`set_active_tool`, which only mutates this instance's pinokin Robot. + """ + import parol6.PAROL6_ROBOT as PAROL6_ROBOT + + if PAROL6_ROBOT.collision is None: + return False + self._load_q_buf(q_rad) + return PAROL6_ROBOT.collision.in_collision(self._q_buf) + + def check_trajectory(self, q_path_rad: NDArray[np.float64]) -> int: + """Returns first colliding row index in `q_path_rad`, or -1 if clear. + + `q_path_rad` is (N, nq) joint positions in radians. + """ + import parol6.PAROL6_ROBOT as PAROL6_ROBOT + + if PAROL6_ROBOT.collision is None: + return -1 + return PAROL6_ROBOT.collision.check_path( + np.ascontiguousarray(q_path_rad, dtype=np.float64) + ) + + def colliding_pairs(self, q_rad: NDArray[np.float64]) -> list[tuple[str, str]]: + """Return list of (name, name) geometry pairs in collision at `q_rad`. + + Names are URDF link names for arm geometry (e.g. ``"L4_0"``) and + the user-supplied name for runtime-attached geometry (e.g. + ``"ssg48_body_simplified.stl"`` for the active tool's body mesh). Tool + geometry is present only when ``PAROL6_ROBOT.apply_tool`` attached it in + this process (see :meth:`in_collision`). + """ + import parol6.PAROL6_ROBOT as PAROL6_ROBOT + + if PAROL6_ROBOT.collision is None: + return [] + self._load_q_buf(q_rad) + return PAROL6_ROBOT.collision.colliding_pairs(self._q_buf) + + def min_distance(self, q_rad: NDArray[np.float64]) -> float: + """Return the minimum clearance over all active pairs at `q_rad`. + + Positive => separation; negative => penetration depth. + Returns +inf when collision checking is disabled. + """ + import parol6.PAROL6_ROBOT as PAROL6_ROBOT + + if PAROL6_ROBOT.collision is None: + return float("inf") + self._load_q_buf(q_rad) + return PAROL6_ROBOT.collision.min_distance(self._q_buf) + def ik_batch( self, poses: NDArray[np.float64], diff --git a/parol6/tools.py b/parol6/tools.py index 42f0b2f..da015ec 100644 --- a/parol6/tools.py +++ b/parol6/tools.py @@ -508,9 +508,13 @@ def _make_tcp_transform( # --------------------------------------------------------------------------- _PNEUMATIC_VERTICAL_MESHES = ( - MeshSpec(file="pneumatic_gripper_vertical_body.stl", role=MeshRole.BODY), - MeshSpec(file="pneumatic_gripper_vertical_right_jaw.stl", role=MeshRole.JAW), - MeshSpec(file="pneumatic_gripper_vertical_left_jaw.stl", role=MeshRole.JAW), + MeshSpec(file="pneumatic_gripper_vertical_body_simplified.stl", role=MeshRole.BODY), + MeshSpec( + file="pneumatic_gripper_vertical_right_jaw_simplified.stl", role=MeshRole.JAW + ), + MeshSpec( + file="pneumatic_gripper_vertical_left_jaw_simplified.stl", role=MeshRole.JAW + ), ) _PNEUMATIC_VERTICAL_MOTION = ( LinearMotion( @@ -524,9 +528,15 @@ def _make_tcp_transform( ) _PNEUMATIC_HORIZONTAL_MESHES = ( - MeshSpec(file="pneumatic_gripper_horizontal_body.stl", role=MeshRole.BODY), - MeshSpec(file="pneumatic_gripper_horizontal_right_jaw.stl", role=MeshRole.JAW), - MeshSpec(file="pneumatic_gripper_horizontal_left_jaw.stl", role=MeshRole.JAW), + MeshSpec( + file="pneumatic_gripper_horizontal_body_simplified.stl", role=MeshRole.BODY + ), + MeshSpec( + file="pneumatic_gripper_horizontal_right_jaw_simplified.stl", role=MeshRole.JAW + ), + MeshSpec( + file="pneumatic_gripper_horizontal_left_jaw_simplified.stl", role=MeshRole.JAW + ), ) _PNEUMATIC_HORIZONTAL_MOTION = ( LinearMotion( @@ -581,15 +591,15 @@ def _make_tcp_transform( ) _SSG48_FINGER_MESHES = ( - MeshSpec(file="ssg48_body.stl", role=MeshRole.BODY), - MeshSpec(file="ssg48_finger_right.stl", role=MeshRole.JAW), - MeshSpec(file="ssg48_finger_left.stl", role=MeshRole.JAW), + MeshSpec(file="ssg48_body_simplified.stl", role=MeshRole.BODY), + MeshSpec(file="ssg48_finger_right_simplified.stl", role=MeshRole.JAW), + MeshSpec(file="ssg48_finger_left_simplified.stl", role=MeshRole.JAW), ) _SSG48_PINCH_MESHES = ( - MeshSpec(file="ssg48_body.stl", role=MeshRole.BODY), - MeshSpec(file="ssg48_pinch_right.stl", role=MeshRole.JAW), - MeshSpec(file="ssg48_pinch_left.stl", role=MeshRole.JAW), + MeshSpec(file="ssg48_body_simplified.stl", role=MeshRole.BODY), + MeshSpec(file="ssg48_pinch_right_simplified.stl", role=MeshRole.JAW), + MeshSpec(file="ssg48_pinch_left_simplified.stl", role=MeshRole.JAW), ) register_tool( @@ -646,21 +656,21 @@ def _make_tcp_transform( ) _MSG_100_MESHES = ( - MeshSpec(file="msg_ai_100_body.stl", role=MeshRole.BODY), - MeshSpec(file="msg_ai_100_right_jaw.stl", role=MeshRole.JAW), - MeshSpec(file="msg_ai_100_left_jaw.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_100_body_simplified.stl", role=MeshRole.BODY), + MeshSpec(file="msg_ai_100_right_jaw_simplified.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_100_left_jaw_simplified.stl", role=MeshRole.JAW), ) _MSG_150_MESHES = ( - MeshSpec(file="msg_ai_150_body.stl", role=MeshRole.BODY), - MeshSpec(file="msg_ai_150_right_jaw.stl", role=MeshRole.JAW), - MeshSpec(file="msg_ai_150_left_jaw.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_150_body_simplified.stl", role=MeshRole.BODY), + MeshSpec(file="msg_ai_150_right_jaw_simplified.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_150_left_jaw_simplified.stl", role=MeshRole.JAW), ) _MSG_200_MESHES = ( - MeshSpec(file="msg_ai_200_body.stl", role=MeshRole.BODY), - MeshSpec(file="msg_ai_200_right_jaw.stl", role=MeshRole.JAW), - MeshSpec(file="msg_ai_200_left_jaw.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_200_body_simplified.stl", role=MeshRole.BODY), + MeshSpec(file="msg_ai_200_right_jaw_simplified.stl", role=MeshRole.JAW), + MeshSpec(file="msg_ai_200_left_jaw_simplified.stl", role=MeshRole.JAW), ) register_tool( @@ -716,7 +726,9 @@ def _make_tcp_transform( name="Vacuum Gripper", description="Vacuum gripper (pneumatic valve I/O)", transform=_make_tcp_transform(z=-0.037), - meshes=(MeshSpec(file="vacuum_gripper_body.stl", role=MeshRole.BODY),), + meshes=( + MeshSpec(file="vacuum_gripper_body_simplified.stl", role=MeshRole.BODY), + ), motions=(), io_port=1, ), diff --git a/parol6/urdf_model/srdf/PAROL6.srdf b/parol6/urdf_model/srdf/PAROL6.srdf new file mode 100644 index 0000000..e8026e7 --- /dev/null +++ b/parol6/urdf_model/srdf/PAROL6.srdf @@ -0,0 +1,32 @@ + + + + + + + + + + + + + + + + + + diff --git a/parol6/urdf_model/urdf/PAROL6.urdf b/parol6/urdf_model/urdf/PAROL6.urdf index ac81a5f..dce672b 100644 --- a/parol6/urdf_model/urdf/PAROL6.urdf +++ b/parol6/urdf_model/urdf/PAROL6.urdf @@ -49,7 +49,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/base_link_simplified.stl" /> @@ -89,7 +89,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L1_simplified.stl" /> @@ -147,7 +147,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L2_simplified.stl" /> @@ -205,7 +205,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L3_simplified.stl" /> @@ -263,7 +263,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L4_simplified.stl" /> @@ -321,7 +321,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L5_simplified.stl" /> @@ -379,7 +379,7 @@ rpy="0 0 0" /> + filename="package://parol6/meshes/L6_simplified.stl" /> diff --git a/parol6/utils/error_catalog.py b/parol6/utils/error_catalog.py index 94b61dc..7ab38fd 100644 --- a/parol6/utils/error_catalog.py +++ b/parol6/utils/error_catalog.py @@ -165,6 +165,12 @@ class _ErrorTemplate: effect="Profile not changed.", remedy="Use one of: TOPPRA, RUCKIG, QUINTIC, TRAPEZOID, LINEAR.", ), + ErrorCode.SYS_SELF_COLLISION: _ErrorTemplate( + title="Self-collision predicted", + cause="Planned configuration would self-collide at sample {sample} of {total}: {pairs}", + effect="Motion command rejected before dispatch.", + remedy="Choose a different target, add intermediate waypoints, or disable via PAROL6_COLLISION_CHECK=0.", + ), } diff --git a/parol6/utils/error_codes.py b/parol6/utils/error_codes.py index 5e32b39..6b6eaec 100644 --- a/parol6/utils/error_codes.py +++ b/parol6/utils/error_codes.py @@ -38,3 +38,4 @@ class ErrorCode(IntEnum): SYS_ESTOP_ACTIVE = 51 SYS_PORT_SAVE_FAILED = 52 SYS_PROFILE_INVALID = 53 + SYS_SELF_COLLISION = 54 diff --git a/pyproject.toml b/pyproject.toml index e281677..e11c840 100644 --- a/pyproject.toml +++ b/pyproject.toml @@ -46,7 +46,7 @@ dependencies = [ "psutil>=5.9", "msgspec>=0.18", "ormsgpack>=1.4.0", - "waldoctl @ git+https://github.com/Jepson2k/waldoctl.git@v0.2.0", + "waldoctl @ git+https://github.com/Jepson2k/waldoctl.git@v0.4.0", ] [tool.setuptools.packages.find] @@ -112,6 +112,14 @@ include = [ [tool.ty.overrides.rules] invalid-type-form = "ignore" +# pinokin is a compiled extension; the lint env's build can predate +# CollisionChecker, so ty can't resolve that symbol (it resolves fine at runtime +# and against a matching pinokin build). +[[tool.ty.overrides]] +include = ["parol6/PAROL6_ROBOT.py"] +[tool.ty.overrides.rules] +unresolved-import = "ignore" + [tool.setuptools] include-package-data = true diff --git a/tests/unit/test_collision_integration.py b/tests/unit/test_collision_integration.py new file mode 100644 index 0000000..106d5be --- /dev/null +++ b/tests/unit/test_collision_integration.py @@ -0,0 +1,195 @@ +"""Unit tests for PAROL6's pinokin collision integration. + +Covers: +- Singleton checker initialization in PAROL6_ROBOT +- SRDF disabled-pair count +- Public Robot.in_collision / colliding_pairs / min_distance / check_trajectory +- guard_joint_path raising TrajectoryPlanningError on a colliding sample +""" + +from __future__ import annotations + +import numpy as np +import pytest + +import parol6.PAROL6_ROBOT as PAROL6_ROBOT +import parol6.config # noqa: F401 - imports trigger collision-checker init +from parol6 import Robot +from parol6.commands._collision_guard import guard_joint_path +from parol6.utils.error_codes import ErrorCode +from parol6.utils.errors import TrajectoryPlanningError + + +def test_singleton_checker_initialized(): + assert PAROL6_ROBOT.collision is not None + assert PAROL6_ROBOT.collision.num_geometry_objects > 0 + assert PAROL6_ROBOT.collision.num_collision_pairs > 0 + + +def test_srdf_disabled_pairs_reduce_pair_count(): + # Without SRDF: 7 link geometries -> 21 pairs minus 6 parent/child adjacent = 15. + # The bundled SRDF disables 7 more pairs (base<->L4/L5/L6, L1<->L4/L5/L6, L2<->L4). + assert PAROL6_ROBOT.collision.num_collision_pairs == 8 + + +def test_home_is_clear(): + q = np.zeros(PAROL6_ROBOT.robot.nq) + assert PAROL6_ROBOT.collision.in_collision(q) is False + + +def test_robot_collision_methods_clear_at_home(): + """Public Robot collision methods report clear at/near home on one instance. + (Robot defines no __del__; an unstarted instance holds no subprocess, so the + old per-test try/finally del was a no-op.)""" + r = Robot() + q = np.zeros(6) + assert r.in_collision(q) is False + d = r.min_distance(q) + assert d > 0.0 and d != float("inf") + # Tiny perturbation around home — definitely clear. + q_path = np.linspace(np.zeros(6), 0.01 * np.ones(6), 5) + assert r.check_trajectory(q_path) == -1 + + +def test_guard_joint_path_clear_returns_none(): + positions = np.zeros((10, 6)) + # No exception means no collision detected. + guard_joint_path(positions) + + +def test_guard_joint_path_raises_on_explicit_collision(monkeypatch): + """Force a fake collision by patching the singleton checker temporarily. + monkeypatch auto-restores the real checker at teardown.""" + + class FakeChecker: + def in_collision(self, q): + return True + + def check_path(self, q): + return 2 + + def colliding_pairs(self, q): + return [("ssg48_body_simplified.stl", "L4_0")] + + monkeypatch.setattr(PAROL6_ROBOT, "collision", FakeChecker()) + + positions = np.zeros((5, 6)) + with pytest.raises(TrajectoryPlanningError) as exc_info: + guard_joint_path(positions) + err = exc_info.value.robot_error + assert err.code == int(ErrorCode.SYS_SELF_COLLISION) + # Cause string should embed the named pair, not raw int indices. + assert "ssg48_body_simplified.stl vs L4_0" in err.cause + + +def test_guard_disabled_when_checker_is_none(monkeypatch): + monkeypatch.setattr(PAROL6_ROBOT, "collision", None) + positions = np.zeros((5, 6)) + # No exception, returns None (no-op). + assert guard_joint_path(positions) is None + + +def test_no_spurious_self_overlap_at_home_or_joint_limits(): + """Audit the bundled simplified collision STLs against the SRDF. + + Asserts that the checker reports no colliding pairs at home, at each + joint's lower/upper limit (single-axis), at every (low, high) corner + of the joint-limit hypercube, and across a handful of seeded random + configs. If this fails, the assertion message identifies the named + pair — add it to parol6/urdf_model/srdf/PAROL6.srdf and re-run. + """ + import itertools + + lo = PAROL6_ROBOT._joint_limits_radian[:, 0] + hi = PAROL6_ROBOT._joint_limits_radian[:, 1] + checker = PAROL6_ROBOT.collision + + configs: list[tuple[str, np.ndarray]] = [("home", np.zeros(6))] + for j in range(6): + q_lo = np.zeros(6) + q_lo[j] = lo[j] + q_hi = np.zeros(6) + q_hi[j] = hi[j] + configs.append((f"J{j}=low", q_lo)) + configs.append((f"J{j}=high", q_hi)) + + for bits in itertools.product((0, 1), repeat=6): + q = np.where(np.array(bits, dtype=bool), hi, lo) + configs.append((f"corner_{''.join(map(str, bits))}", q)) + + rng = np.random.default_rng(0xC011) + for k in range(20): + configs.append((f"rand_{k}", rng.uniform(lo, hi))) + + failures: list[str] = [] + for label, q in configs: + pairs = checker.colliding_pairs(np.ascontiguousarray(q, dtype=np.float64)) + if pairs: + failures.append(f"{label}: {pairs}") + + assert not failures, ( + "Spurious self-collision in the bundled simplified STLs. Add these " + "pairs to parol6/urdf_model/srdf/PAROL6.srdf and re-run:\n" + + "\n".join(failures[:10]) + + (f"\n... ({len(failures) - 10} more)" if len(failures) > 10 else "") + ) + + +def test_collision_check_speed_diagnostic(capsys): + """Time in_collision and colliding_pairs across a sampled workspace. + + Diagnostic only — does not assert a threshold. The per-tick mid-motion + collision check shipped (JogL release-decel gate, JogJ stop); this prints + percentiles to confirm its cost stays well within the 100 Hz tick budget + (10 ms). + + Run via: pytest tests/unit/test_collision_integration.py::test_collision_check_speed_diagnostic -v -s + """ + import time + + rng = np.random.default_rng(0xC0FFEE) + lo = PAROL6_ROBOT._joint_limits_radian[:, 0] + hi = PAROL6_ROBOT._joint_limits_radian[:, 1] + qs = [np.zeros(6)] + [ + np.ascontiguousarray(rng.uniform(lo, hi), dtype=np.float64) for _ in range(99) + ] + c = PAROL6_ROBOT.collision + + # warm-up so first-call cache effects don't dominate + for q in qs[:10]: + c.in_collision(q) + c.colliding_pairs(q) + + t_bool: list[int] = [] + for q in qs: + t0 = time.perf_counter_ns() + c.in_collision(q) + t_bool.append(time.perf_counter_ns() - t0) + + t_pairs: list[int] = [] + for q in qs: + t0 = time.perf_counter_ns() + c.colliding_pairs(q) + t_pairs.append(time.perf_counter_ns() - t0) + + def pct(a: list[int], p: float) -> float: + return float(np.percentile(a, p)) / 1000.0 # ns -> us + + with capsys.disabled(): + print( + f"\nin_collision us:" + f" min={pct(t_bool, 0):.1f}" + f" med={pct(t_bool, 50):.1f}" + f" p95={pct(t_bool, 95):.1f}" + f" p99={pct(t_bool, 99):.1f}" + f" max={pct(t_bool, 100):.1f}" + ) + print( + f"colliding_pairs us:" + f" min={pct(t_pairs, 0):.1f}" + f" med={pct(t_pairs, 50):.1f}" + f" p95={pct(t_pairs, 95):.1f}" + f" p99={pct(t_pairs, 99):.1f}" + f" max={pct(t_pairs, 100):.1f}" + ) + print("servo tick budget: 10000 us (100 Hz)")