Updating codebase and whatnot

.gitignore

@@ -4,6 +4,7 @@
 private/
 .vscode/
 saved_cuts/
+generated_assets/
 *~$*
 
 # Byte-compiled / optimized / DLL files

README.md

@@ -2,15 +2,17 @@
 A CNC controller that learns material characteristics and optimizes its own feeds and speeds.
 
 # Project Status
+Nearing completion, collecting test data
+
 ## Current Goals
 The current goal of this project is to make a system that faces a material using an endmill while simultaneously performing regression on sensor data to complete its model. This model is used to optimize subsequent passes (feedrate and WOC) by means of an objective function that weighs MMR against the chance of failure (deflection, breakage, spindle overload).
 
 ## Modeling
 Models for forces experienced during the cutting process and models for tool / machine failure are in [software/models.py](software/models.py).
 
-The linear model converges well when given test data sweeps.
+The linear model converges well when given test data sweeps. 
 
-![](assets/model_converge.png)
+![](assets/6061-sweep-wide_forces.png)
 
 ## Hardware
 The hardware setup is finished. The machine is a Taig Micro Mill (kindly donated by Ted Hall).

software/ammp.py

 """
-Intended to be the brain box of this project; for now, it just runs a test sweep to collect initial data.
+Intended to be the brain box of this project.
 """
+FAKE = False
+
 import numpy as np
 import time
+import shelve
+import logging
+import os
 
+# hacky fix for issues with serial library
+if not FAKE:
+    from cut import Cut
 from objects import EndMill, Conditions, MachineChar
-from cut import Cut
-from ml import LinearModel
-from optimize import Optimizer
+from fake_cut import ReplayCut
+from models import T_lin, F_lin, T_lin_full, F_lin_full
+from ml import UnifiedLinearModel, UnifiedLinearModelFull
+from optimize import Optimizer #, OptimizerFull, OptimizerPSO, OptimizerPSOFull
 
-import logging
 logging.basicConfig(level="INFO")
 
 MACHINE_PORT = '/dev/ttyS25' 
 SPINDLE_PORT = '/dev/ttyS33'
-TFD_PORT     = '/dev/ttyS35'
+TFD_PORT     = '/dev/ttyS36'
+
+# input variables
+D = 1e-3 # depth of cut (always unchanging...)
+W = 1e-3 # initial width of cut for bootstrap
+f_r = 0.001 # initial feedrate for bootstrap
+f_r_clearing = 0.003 # feedrate for facing and cutting start groove
+w = 200 # spindle speed
+START_DEPTH = 0.0e-3
+START_FACE_D = 0.2e-3
+ENDMILL = EndMill(3, 3.175e-3, 3.175e-3, 12e-3, 5e-3)
+# ENDMILL = EndMill(3, 9.525e-3/2, 9.525e-3/2, 12.7e-3, 5e-3)
+D_A = 0.1e-3 # maximum allowable deflection
+N = 50 # total number of cuts to take, including bootstrap cuts
+CONFIDENCE_RATE = np.linspace(0.2, 1, 5) # confidence progression during bootstrap cuts
+USE_OLD_DATA = False
+
+NAME = "ammp-lcs-1_4" # name to save to / name to draw data from if doing a fake cut
+MODEL = UnifiedLinearModel
+EQUATIONS = (T_lin, F_lin)
+OPTIMIZER = Optimizer # optimizer to use
+
+# taig machine
+MACHINE = MachineChar(
+    r_e = 1, 
+    K_T = 0.10281,
+    R_w = 0.188,
+    V_max = 48,
+    I_max = 10,
+    T_nom = 0.12,
+    f_r_max = 0.01,
+    K_machine = 1.25e6,
+    D_a = D_A
+)
+
+FIXED_CONDITIONS = Conditions(
+    D = D,
+    W = W,
+    f_r = f_r,
+    w = w,
+    endmill = ENDMILL
+)
+
+logging.info("Initializing all structures")
+
+cut = None
+if FAKE:
+    cut = ReplayCut(NAME, MODEL(), *EQUATIONS, [0,0], [0.1,2])
+else:
+    cut = Cut(MACHINE_PORT, SPINDLE_PORT, TFD_PORT, ENDMILL, 80e-3, 50.8e-3, f_r_clearing, w, START_DEPTH, NAME)
+model = MODEL()
+optimizer = OPTIMIZER(model, MACHINE, D_A, FIXED_CONDITIONS)
 
-endmill = EndMill(3, 3.175e-3, 3.175e-3, 19.05e-3, 1e-3)
+logging.info("Beginning facing operation, creating starting groove")
+if START_FACE_D:
+    cut.face_layer(START_FACE_D)
+cut.begin_layer(D)
 
-cut = Cut(MACHINE_PORT, SPINDLE_PORT, TFD_PORT, endmill, 80e-3, 50.8e-3, 5e-3, 300, save_as = "6061-sweep")
+logging.info("First bootstrap cut to obtain a basic characterization")
 
-f_r_range = np.linspace(2e-3, 5e-3, 9)
-W_range = np.linspace(1e-3, 3.175e-3, 10)
+conditions_conservative = Conditions(D, W, f_r, w, ENDMILL)
+datum = cut.cut(conditions_conservative, save=True, auto_layer=True)
+model.ingest_datum(datum)
 
-cut.face_layer(D = 0.3e-3)
+logging.info("After bootstrap cut, model params are actually at: " + ", ".join(["{:.5e}".format(p) for p in model.params]))
+if USE_OLD_DATA and not FAKE:
+    with shelve.open(os.path.join("saved_cuts", "db")) as db:
+        model.ingest_data(db[USE_OLD_DATA])
+logging.info("Partially optimized bootstrap cuts starting now")
 
-cut.begin_layer(D = 1e-3)
+# start optimizing, but only slowly start accepting new datums
+confidences = list(CONFIDENCE_RATE) + [1] * (N - len(CONFIDENCE_RATE))
+for confidence in confidences:
+    logging.info("Confidence at    : " + str(confidence))
+    conditions_optimized = optimizer.optimize(verbose = True)
+    logging.info("Optimized        : " + str(conditions_optimized))
+    conditions_compromise = conditions_conservative.compromise(conditions_optimized, confidence)
+    logging.info("Compromised      : " + str(conditions_compromise))
+    logging.info("Model guesses    : " + str(model.predict_one(conditions_compromise)))
+    datum = cut.cut(conditions_compromise, save = True, auto_layer=True)
+    logging.info("Datum obtained   : " + str(datum))
+    model.ingest_datum(datum)
+    logging.info("Params updated to: " + ", ".join(["{:.5e}".format(p) for p in model.params]))
 
-for f_r in f_r_range: 
-    for W in W_range:
-        conditions = Conditions(1e-3, W, f_r, 300, endmill)
-        cut.cut(conditions, save = True, auto_layer=True)
-        
-cut.close()
\ No newline at end of file
+if FAKE:
+    logging.info("Actual cut params: " + ", ".join(["{:.5e}".format(p) for p in cut.params]))
\ No newline at end of file

software/collect_data.py

+"""
+Intended to be the brain box of this project; for now, it just runs a test sweep to collect initial data.
+"""
+import numpy as np
+import time
+
+from objects import EndMill, Conditions, MachineChar
+from cut import Cut
+from ml import LinearModel
+from optimize import Optimizer
+
+import logging
+logging.basicConfig(level="INFO")
+
+MACHINE_PORT = '/dev/ttyS25' 
+SPINDLE_PORT = '/dev/ttyS33'
+TFD_PORT     = '/dev/ttyS36'
+IGNORE_FIRST = 0
+
+machine = MachineChar(
+    r_e = 1, 
+    K_T = 0.10281,
+    R_w = 0.188,
+    V_max = 48,
+    I_max = 10,
+    T_nom = 0.12,
+    f_r_max = 0.017,
+    K_machine = 5e6,
+    D_a = 1
+)
+endmill = EndMill(3, 3.175e-3, 3.175e-3, 9.5e-3, 3e-3)
+
+fixed_conditions = Conditions(
+    D = 1e-3,
+    W = 1e-3,
+    f_r = 0.001,
+    w = 300,
+    endmill = endmill
+)
+
+cut = Cut(MACHINE_PORT, SPINDLE_PORT, TFD_PORT, endmill, 80e-3, 50.8e-3, 5e-3, 300, save_as = "6061-sweep-speed")
+
+f_r_range = np.linspace(2e-3, 0.011, 4)
+W_range = np.linspace(1e-3, 3.175e-3 * 1.8, 5)
+w_range = np.linspace(100, 300, 5)
+
+
+cut.face_layer(D = 0.3e-3)
+
+cut.begin_layer(D = 1e-3)
+
+for f_r in f_r_range: 
+    for W in W_range:
+        for w in w_range:
+            conditions = Conditions(1e-3, W, f_r, w, endmill)
+            cut.cut(conditions, save = True, auto_layer=True)
+        
+cut.close()
\ No newline at end of file

software/cut.py

@@ -16,8 +16,8 @@ class MachineCrash(Exception):
 
 
 class Cut:
-    def __init__(self, machine_port, spindle_port, tfd_port, endmill, x_max, y_max, f_r_clearing, w_clearing, initial_z=0, save_as=None):
-        self.machine = Machine(machine_port)
+    def __init__(self, machine_port, spindle_port, tfd_port, endmill, x_max, y_max, f_r_clearing, w_clearing, initial_z=0, save_as=None, graceful_shutdown = False):
+        self.machine = Machine(machine_port, graceful_shutdown = graceful_shutdown)
         self.machine.unlock()
         self.machine.zero()
         self.spindle = Spindle_Applied(spindle_port)
@@ -111,10 +111,10 @@ class Cut:
         self.spindle.set_w(self.w_clearing)
 
         self.machine.rapid({'x': self.X_START, 'y': self.Y_START})
-        self.machine.rapid({'z': self.cut_z})
+        self.machine.rapid({'z': self.cut_z + D / 2})
         self.machine.cut({'y': self.Y_END}, self.f_r_clearing)
-        self.machine.rapid({'z': self.cut_z + D + 1e-3})
-        self.machine.rapid({'x': self.X_START, 'y': self.Y_START})
+        self.machine.rapid({'z': self.cut_z})
+        self.machine.cut({'y': self.Y_START}, self.f_r_clearing)
         self.machine.rapid({'z': self.cut_z})
         self.machine.hold_until_still()
 

software/fake_cut.py

-from models import T_lin, F_lin
+from models import T_lin, F_lin, T_lin_full, F_lin_full
 from objects import Conditions, Data
 import numpy as np
 import shelve
 import os
+from ml import UnifiedLinearModel
 
+import logging
+log = logging.getLogger(__name__)
 
 class Fake_Cut:
     """
     Fake cutting process. Returns results using prebaked parameters and specified noise levels.
 
     Args:
-        params: list of format [K_tc, K_te, K_rc, K_re]
+        params: list of params
+        T_func: A function to use for torques
+        F_func: A function to use for forces
         error: list of standard deviations of format [o_T, o_Fy]. Simulates the sensor being "wrong" sometimes.
         error: list of standard deviations of format [o_T, o_Fy]. Simulates the sensor being noisy.
     """
 
-    def __init__(self, params, error, noise):
+    def __init__(self, params, T_func, F_func, error, noise):
         self.params = params
+        self.T_func = T_func
+        self.F_func = F_func
         self.error = error
         self.noise = noise
+        log.info("Initialized fake cut with params: " + str(self.params))
 
-    def begin_cut(self, *args, **kwargs):
+    def face_layer(self, *args, **kwargs):
+        log.info("Face cut called")
         pass
 
-    def cut(self, conditions: Conditions):
+    def begin_layer(self, *args, **kwargs):
+        log.info("Begin cut called")
+        pass
+
+    def cut(self, conditions: Conditions, *args, **kwargs):
         # use prediction as output
-        T = T_lin(conditions, *self.params[:2])
-        _, Fy = F_lin(conditions, *self.params)
+        T = self.T_func(conditions, *self.params)
+        _, Fy = self.F_func(conditions, *self.params)
         # add sensor error
         T_error = np.random.normal(T, self.error[0])
         Fy_error = np.random.normal(Fy, self.error[1])
@@ -36,18 +49,17 @@ class Fake_Cut:
         # generate fake times
         t = np.linspace(0, 1, 100)
         # return fake reading
-        return Data(*conditions.unpack(), np.array([t, T_noisy]), np.array([t, Fy_noisy]))
+        data = Data(*conditions.unpack(), np.array([t, T_noisy]).T, np.array([t, Fy_noisy]).T)
+        return data
 
+    def scale_coefs(self, scale):
+        self.params = [scale * p for p in self.params]
 
-class ReplayCut:
-    def __init__(self, replay_data):
-        self.data = None
-        with shelve.open(os.path.join("saved_data", "db")) as db:
-            self.data = db[replay_data]
-
-    def begin_cut(self, *args, **kwargs):
-        pass
 
-    def cut(self, *args, **kwargs):
-        for datum in self.data:
-            yield datum
+class ReplayCut(Fake_Cut):
+    def __init__(self, replay_data, model, T_func, F_func, error, noise):
+        self.model = model
+        with shelve.open(os.path.join("saved_cuts", "db")) as db:
+            data = db[replay_data]
+            self.model.ingest_data(data)
+        super().__init__(self.model.params, T_func, F_func, error, noise)
\ No newline at end of file

software/ml.py

@@ -2,11 +2,18 @@ import abc
 import numpy as np
 
 from sklearn import linear_model
+from scipy import stats
 from matplotlib import pyplot as plt
 
-from models import T_lin, F_lin, T_x_vector, T_x_vector_padded, Fy_x_vector
+from models import T_lin, F_lin, T_lin_full, F_lin_full, T_x_vector, T_x_vector_padded, Fy_x_vector, T_x_vector_full, Fy_x_vector_full
 from objects import Data, Conditions, EndMill, Prediction
 
+# https://stackoverflow.com/questions/11686720
+def mean_no_outliers(data, m=2):
+    d = np.abs(data - np.median(data))
+    mdev = np.median(d)
+    s = d / (mdev if mdev else 1.)
+    return np.mean(data[s < m])
 
 class Model(abc.ABC):
     """
@@ -37,7 +44,7 @@ class Model(abc.ABC):
 
 
 class LinearModel(Model):
-    def __init__(self):
+    def __init__(self, initial_params = [0, 0, 0, 0]):
         self.training_T_x = list()
         self.training_T_y = list()
         self.training_Fy_x = list()
@@ -45,12 +52,12 @@ class LinearModel(Model):
 
         self.regressor_T = linear_model.LinearRegression(fit_intercept=False)
         self.regressor_Fy = linear_model.LinearRegression(fit_intercept=False)
-        self.params = np.array([0, 0, 0, 0], dtype='float64')
+        self.params = initial_params
 
     def ingest_datum(self, datum):
         # decompose
         _, _, _, _, _, Ts, Fys = datum.unpack()
-        T, Fy = np.median(Ts[:, 1]), np.median(Fys[:, 1])
+        T, Fy = mean_no_outliers(Ts[:, 1]), mean_no_outliers(Fys[:, 1])
         # get linear coefficients
         T_x = T_x_vector(datum.conditions())
         Fy_x = Fy_x_vector(datum.conditions())
@@ -83,35 +90,39 @@ class LinearModel(Model):
 
     def predict_one(self, conditions):
         # evaluate
-        T = T_lin(conditions, *self.params[:2])
+        T = T_lin(conditions, *self.params)
         F = F_lin(conditions, *self.params)
 
         # repack and return
         return Prediction(*conditions.unpack(), T, F)
 
 class UnifiedLinearModel(Model):
-    def __init__(self):
+    def __init__(self, initial_params = [0,0,0,0]):
         self.training_Tx = list()
         self.training_Ty = list()
         self.training_Fyx = list()
         self.training_Fyy = list()
 
         self.regressor = linear_model.LinearRegression(fit_intercept=False)
-        self.params = np.array([0, 0, 0, 0], dtype='float64')
+        self.params = initial_params
 
     def ingest_datum(self, datum):
         # decompose
         _, _, _, _, _, Ts, Fys = datum.unpack()
-        T, Fy = np.median(Ts[:, 1]), np.median(Fys[:, 1])
+        # mean filter + rejection of outliers
+        # T, Fy = np.median(Ts[:, 1]), np.median(Fys[:, 1])
+        T, Fy = mean_no_outliers(Ts[:, 1]), mean_no_outliers(Fys[:, 1])
         # get linear coefficients
         T_x = np.array(T_x_vector_padded(datum.conditions()))
         Fy_x = np.array(Fy_x_vector(datum.conditions()))
 
-        # we want to artificially inflate T to be as big as F
-        # this is a little arbitrary, might not be the best idea lol
-        ratio = Fy_x[:2].mean() / T_x[:2].mean()
-        T_x *= ratio
-        T *= ratio
+        # normalizing independently while preserving ratios
+        norm_T = np.linalg.norm(T_x)
+        T_x /= norm_T
+        T /= norm_T
+        norm_Fy = np.linalg.norm(Fy_x)
+        Fy_x /= norm_Fy
+        Fy /= norm_Fy
 
         # add T to training set
         self.training_Tx.append(T_x)
@@ -130,14 +141,70 @@ class UnifiedLinearModel(Model):
 
     def predict_one(self, conditions):
         # evaluate
-        T = T_lin(conditions, *self.params[:2])
+        T = T_lin(conditions, *self.params)
         F = F_lin(conditions, *self.params)
 
         # repack and return
         return Prediction(*conditions.unpack(), T, F)
 
+    def score(self):
+        return self.regressor.score(self.training_Tx + self.training_Fyx, self.training_Ty + self.training_Fyy)
+
+
+class UnifiedLinearModelFull(Model):
+    def __init__(self, initial_params = [0,0,0,0,0,0]):
+        self.training_Tx = list()
+        self.training_Ty = list()
+        self.training_Fyx = list()
+        self.training_Fyy = list()
+
+        self.regressor = linear_model.LinearRegression(fit_intercept=False)
+        self.params = initial_params
+
+    def ingest_datum(self, datum):
+        # decompose
+        _, _, _, _, _, Ts, Fys = datum.unpack()
+        # mean filter + rejection of outliers
+        # T, Fy = np.median(Ts[:, 1]), np.median(Fys[:, 1])
+        T_f, Fy_f = reject_outliers(Ts[:, 1]), reject_outliers(Fys[:, 1])
+        T, Fy = np.mean(T_f), np.mean(Fy_f)
+        # get linear coefficients
+        T_x = np.array(T_x_vector_full(datum.conditions()))
+        Fy_x = np.array(Fy_x_vector_full(datum.conditions()))
+
+        # normalizing independently while preserving ratios
+        norm_T = np.linalg.norm(T_x)
+        T_x /= norm_T
+        T /= norm_T
+        norm_Fy = np.linalg.norm(Fy_x)
+        Fy_x /= norm_Fy
+        Fy /= norm_Fy
+
+        # add T to training set
+        self.training_Tx.append(T_x)
+        self.training_Ty.append(T)
+
+        # add Fy to training set
+        self.training_Fyx.append(Fy_x)
+        self.training_Fyy.append(Fy)
+
+        self.update()
+
+    def update(self):
+        # calculate best fit from data
+        self.regressor.fit(self.training_Tx + self.training_Fyx, self.training_Ty + self.training_Fyy)
+        self.params = np.array(self.regressor.coef_)
+
+    def predict_one(self, conditions):
+        # evaluate
+        T = T_lin_full(conditions, *self.params)
+        F = F_lin_full(conditions, *self.params)
+
+        # repack and return
+        return Prediction(*conditions.unpack(), T, F)
+
 class RANSACLinearModel(Model):
-    def __init__(self):
+    def __init__(self, initial_params = [0,0,0,0]):
         self.training_Tx = list()
         self.training_Ty = list()
         self.training_Fyx = list()
@@ -145,7 +212,7 @@ class RANSACLinearModel(Model):
 
         base_regressor = linear_model.LinearRegression(fit_intercept=False)
         self.regressor = linear_model.RANSACRegressor(base_regressor, min_samples=5)
-        self.params = np.array([0, 0, 0, 0], dtype='float64')
+        self.params = initial_params
 
     def ingest_datum(self, datum):
         # decompose
@@ -179,7 +246,70 @@ class RANSACLinearModel(Model):
 
     def predict_one(self, conditions):
         # evaluate
-        T = T_lin(conditions, *self.params[:2])
+        T = T_lin(conditions, *self.params)
+        F = F_lin(conditions, *self.params)
+
+        # repack and return
+        return Prediction(*conditions.unpack(), T, F)
+
+class BayesianLinearModel(Model):
+    """
+    Utilizes a Bayesian approach to pick "safe" values for the coefficients.
+    That is, we have a confidence interval for our parameters. We pick the upper end for
+        each coefficient so we don't make too aggressive of a cut
+    """
+    def __init__(self, initial_params = [0,0,0,0], percentile = .90):
+        self.training_Tx = list()
+        self.training_Ty = list()
+        self.training_Fyx = list()
+        self.training_Fyy = list()
+
+        self.regressor = linear_model.ARDRegression(fit_intercept=False, tol = 1e-6, alpha_1 = 1e-9, alpha_2 = 1e-9, lambda_1 = 1e-9, lambda_2 = 1e-9)
+        self.params = initial_params
+        self.zscore = stats.norm.ppf(percentile)
+
+    def ingest_datum(self, datum):
+        # decompose
+        _, _, _, _, _, Ts, Fys = datum.unpack()
+        T, Fy = np.median(Ts[:, 1]), np.median(Fys[:, 1])
+        # get linear coefficients
+        T_x = np.array(T_x_vector_padded(datum.conditions()))
+        Fy_x = np.array(Fy_x_vector(datum.conditions()))
+
+        # normalize while preserving ratio between x and y
+        norm_T = np.linalg.norm(T_x)
+        T_x /= norm_T
+        T /= norm_T
+        norm_Fy = np.linalg.norm(Fy_x)
+        Fy_x /= norm_Fy
+        Fy /= norm_Fy
+
+        # add T to training set
+        self.training_Tx.append(T_x)
+        self.training_Ty.append(T)
+
+        # add Fy to training set
+        self.training_Fyx.append(Fy_x)
+        self.training_Fyy.append(Fy)
+
+        self.update()
+
+    def update(self):
+        # calculate best fit from data
+        self.regressor.fit(self.training_Tx + self.training_Fyx, self.training_Ty + self.training_Fyy)
+
+        # get params and variance matrix, convert to std deviation
+        param_mean = np.array(self.regressor.coef_)
+        param_stdv = np.sqrt(np.diag(self.regressor.sigma_))
+        print("Param mean: ", param_mean)
+        print("param stdv: ", param_stdv)
+
+        # set params to the lower end of our confidence interval, but make sure they're above 0
+        self.params = param_mean
+
+    def predict_one(self, conditions):
+        # evaluate
+        T = T_lin(conditions, *self.params)
         F = F_lin(conditions, *self.params)
 
         # repack and return

software/models.py

@@ -4,13 +4,13 @@ from objects import Conditions, Data, Prediction, MachineChar
 
 
 def calc_f_t(conditions: Conditions):
-    D, W, f_r, w, endmill = conditions.unpack()
+    _, _, f_r, w, endmill = conditions.unpack()
     N = endmill.N
     return (2 * np.pi * f_r) / (N * w)
 
 
 def calc_h_a(conditions: Conditions):
-    D, W, f_r, w, endmill = conditions.unpack()