feat: replay live PPS telemetry in fixed-point model

2026-07-29 00:16:43 +03:00
parent a697284bff
commit 9b0828dbaa
10 changed files with 3019 additions and 12 deletions
@@ -7,3 +7,8 @@
 # Generated build outputs.
 /out/
 /soc/out/
+
+# Python runtime caches and privacy-sensitive raw board captures.
+__pycache__/
+*.py[cod]
+/soc/software/pps_end_to_end_validation/hardware_logs/*.csv
@@ -93,11 +93,13 @@ Generated results are in `output/stability/`:
  capture, HDOP/VDOP/TDOP/GDOP, C/N0, pseudorange noise, clock sigma/drift,
  oscillator and timing-error inputs.

-The real capture contains 989 GDOP values and 990 tracked-satellite values
-(eight throughout), but no PPS phase/rate, ABS_SAMPLE, C/N0, TDOP/HDOP,
-pseudorange residual, oscillator temperature, or trusted-edge/TIC samples.
-The generated CSV labels its replacements as synthetic; it must not be read as
-board telemetry.
+The older fusion capture used by `stability_analysis.py` contains 989 GDOP
+values and 990 tracked-satellite values (eight throughout), but no PPS
+phase/rate, ABS_SAMPLE, C/N0, TDOP/HDOP, pseudorange residual, oscillator
+temperature, or trusted-edge/TIC samples. The newer live-board workflow below
+supplies many of those PPS status fields, while ABS_SAMPLE, REM_CODE_PHASE,
+temperature, and trusted-edge timing remain unavailable. The stability CSV
+labels replacements as synthetic; it must not be read as board telemetry.

 The current acquire, precision, and robust fixed-point poles are inside the
 unit circle at the 200 ms update rate, and the stress analysis observes no
@@ -113,6 +115,53 @@ candidate. The generated report contains the current numerical comparison.
 The stability analysis does not alter loop constants. Production firmware now
 uses the current-RTL-compatible 180 ms epoch correction described below.

+## Live board telemetry replay
+
+`hardware_replay.py` accepts the host-timestamped UART CSV produced by the
+fusion capture utility. It extracts the firmware fields that actually drive
+or describe PPS: raw/filtered WLS clock bias, innovation, Doppler datum drift,
+TDOP/GDOP/HDOP/VDOP, clock sigma, C/N0, tracked/used satellites, velocity/FDE,
+reference SVID, fractional capture correction, RTL phase residual, rate word,
+integrator, lock/profile, pulse count, and commit sequence.
+
+Capture and replay from `soc/software`:
+
+```bash
+python3 fusion/serial_capture.py \
+  --port /dev/ttyUSB2 --baud 460800 --duration 300 \
+  --output /tmp/genesys2_pps.csv
+
+python3 -m pps_end_to_end_validation.hardware_replay \
+  --input /tmp/genesys2_pps.csv \
+  --output-dir pps_end_to_end_validation/output/hardware_replay
+
+python3 -m unittest \
+  pps_end_to_end_validation.test_hardware_replay
+```
+
+Raw UART files are ignored by Git because `[LOCATION]` records contain exact
+coordinates. The replay output is normalized to PPS fields and deliberately
+omits latitude/longitude.
+
+For an already-running board, replay imports the first logged locked
+filter/PI snapshot. Starting the model from reset would erase the observed
+integrator and create a false acquisition transient. When status is decimated,
+commit sequence numbers expand the trace back to the nominal 200 ms cadence;
+intermediate values are explicitly marked `interpolated=true`.
+
+The report separates three quantities that should not be conflated:
+
+- direct `hw_phase` statistics from the board;
+- fixed-point PI reproduction and a telemetry-conditioned model replay; and
+- inferred active phase obtained by integrating `rate_cmd` under a constant
+  oscillator assumption.
+
+Only the first two are directly constrained by firmware/RTL telemetry. The
+third is useful for diagnosing slow wander but is not a trusted-generator
+measurement. `hw_phase` itself is a 5 Hz commit residual, not the physical PPS
+pin offset. A calibrated, common-clock TIC/scope capture is still required for
+a maximum-20 ns output claim.
+
 ## 20 ms diagnosis

 The current tracking wrapper shifts the current bit into `shift_reg_n`, while
@@ -0,0 +1,150 @@
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@@ -0,0 +1,52 @@
+# Genesys2 live PPS telemetry replay
+
+Source: `pps_end_to_end_validation/hardware_logs/genesys2_pps_20260728.csv`
+
+## Direct firmware/RTL observations
+
+- Samples/duration: 149 / 296.0 s.
+- Status interval: 2.000 s; median sequence step 10 (2.0 s of 200 ms solves).
+- Profiles: robust; locked fraction 1.000; transitions 0; reference SVIDs [23].
+- TDOP/GDOP medians: 1.220 / 2.820; clock sigma median 11.24 m.
+- C/N0 mean/min medians: 42.6 / 38.4 dB-Hz; tracked/used medians 6/5.
+- WLS innovation RMS/p95-absolute: 10.47 / 19.66 m.
+- Raw/filtered bias slopes: -90.020 / -90.025 m/s; PPS velocity residual median 0.079 m/s.
+- Internal hardware phase mean: 155.37 ns; median-centered RMS/p95/max/p-p: 17.92 / 31.26 / 47.95 / 93.21 ns.
+- Ten-second averaged phase wander p-p: 46.16 ns.
+- Sampled phase-step RMS/p95/max: 22.84 / 44.13 / 56.38 ns. These are at the status interval, not consecutive physical 1 PPS edges.
+- Rate command median/span: -1.5370 / 0.0140 ppm; integrator median -1.5600 ppm.
+- Fixed-point PI rate reproduction RMS/p95/max: 0.430 / 0.852 / 0.921 ppb. This is the difference between logged `rate_cmd` and `integrator + Kp*hw_phase`; the remaining error is dominated by three-decimal UART rounding.
+- Phase correlation with rate command / WLS innovation: 0.988 / 0.656.
+- A constant oscillator inferred from zero net frequency is 1.536779 ppm. Integrating the logged command under that assumption gives centered phase RMS/p-p 23.65 / 92.48 ns.
+
+`hw_phase` is the RTL PI residual captured over APB. It is not a trusted-generator time-interval measurement of the output pin, so these values cannot certify physical PPS jitter or absolute offset.
+
+## Telemetry-conditioned end-to-end loop replay
+
+The replay imports the first locked phase/rate/integrator and software filter snapshot instead of incorrectly resetting the board to an acquisition state. It uses raw/filtered clock bias, Doppler datum drift, TDOP/GDOP, clock sigma, C/N0, satellite count, FDE, reference SVID and the production fixed-point coefficients. The reference trajectory is reconstructed from filtered bias, the logged PI residual and the integrated rate command.
+
+- Expanded updates: 1481; interpolation factor 9.94.
+- Snapshot starts locked at 0.00 s; post-warmup locked fraction 1.000; unlocks 0.
+- Constant-oscillator convention: 1.536779 ppm.
+- Modeled physical-grid edge centered RMS/p95/p-p: 41.32 / 80.00 / 168.00 ns.
+- Modeled one-second period RMS/p95/max: 5.51 / 8.00 / 16.00 ns.
+- Modeled PI residual centered RMS/p95/p-p: 21.47 / 46.79 / 135.63 ns.
+- Logged-epoch PI residual reproduction RMS/p95 error: 18.07 / 44.30 ns.
+- Logged-epoch filtered-bias reproduction RMS/p95: 9.87 / 22.13 m.
+
+## Tuning sensitivity on the same trace
+
+| tuning | edge RMS (ns) | edge p-p (ns) | period max (ns) | residual reproduction RMS (ns) | unlocks |
+|---|---:|---:|---:|---:|---:|
+| current | 41.32 | 168.00 | 16.00 | 18.07 | 0 |
+| robust_bias_1_64 | 57.06 | 216.00 | 16.00 | 24.53 | 0 |
+| drift_gain_1_2 | 42.23 | 168.00 | 16.00 | 18.03 | 0 |
+
+These counterfactuals reuse a reference trajectory reconstructed from the current filter, and nine of every ten solve epochs are interpolated. They are useful as a rejection test, not as evidence to deploy new gains. On this capture neither `robust_bias_1_64` nor `drift_gain_1_2` improves the current loop's absolute wander.
+
+## Limits and next measurement
+
+- Missing status epochs are linearly interpolated when sequence step is greater than one. This preserves low-frequency wander but understates unlogged 200 ms noise; it is not an exact firmware replay.
+- The inferred oscillator and active phase assume one constant crystal frequency chosen to make net phase slope zero over this capture. Temperature telemetry was unavailable, so slow crystal motion is not separable from the reconstructed reference.
+- Level-1 telemetry does not expose ABS_SAMPLE, REM_CODE_PHASE, full capture counter, chi-square ratio, pseudorange residual vector, board temperature, or a trusted PPS edge timestamp. The bit/subframe part of the end-to-end model remains synthetic for those fields.
+- Set `GPS_PPS_STATUS_LOG_INTERVAL=1` for exact 200 ms input cadence. For a max-20 ns pin claim, capture DUT and trusted PPS with a common-clock TIC/scope after cable/output-delay calibration.
@@ -9,13 +9,13 @@ This report is generated by `stability_analysis.py`. The absolute LNAV epoch pat
 - DUT minus trusted PPS was 32.01 ns. That remainder is the model's configured four-PCLK capture pipeline, not a measured board delay.
 - Production firmware and this analysis both define `POSTPONE_TOW` as 180 ms for the current RTL delivery semantics.

-## Repository hardware data
+## Hardware data used by this synthetic sweep

 - Real GPS capture: 989 GDOP samples and 990 tracked-satellite samples over about five minutes.
 - GDOP min/median/p95/max: 1.86 / 1.93 / 3.15 / 3.15.
 - Tracked satellites: 8..8 (median 8).
 - Horizontal scatter RMS/p95/max: 8.58 / 15.15 / 23.77 m. No surveyed truth was recorded.
- No real ABS_SAMPLE, REM_CODE_PHASE, TDOP/HDOP, C/N0, pseudorange residual, PPS phase/rate/integrator, temperature, or trusted-edge TIC samples exist in the repository. Those columns in the companion CSV are explicitly synthetic.
+- The older fusion capture used by this sweep has no ABS_SAMPLE, REM_CODE_PHASE, TDOP/HDOP, C/N0, pseudorange residual, PPS phase/rate/integrator, temperature, or trusted-edge TIC samples. Those columns in the companion CSV are explicitly synthetic. Newer PPS status captures are analyzed separately by `hardware_replay.py` and are not silently mixed into this historical baseline.

 Synthetic timing uses the board-calibration values already encoded in the PPS tests: TDOP 1.50, GDOP 2.92, clock sigma 15.87 m (52.94 ns), C/N0 40.3/34.8 dB-Hz, drift noise 3.47 m/s, seven-satellite reference point, -291.75 m/s datum range rate, and 1.592 ppm local oscillator. Real GDOP and satellite count replace the geometry fields when available.

@@ -600,7 +600,7 @@ def write_report(
        "- Production firmware and this analysis both define `POSTPONE_TOW` "
        "as 180 ms for the current RTL delivery semantics.",
        "",
-        "## Repository hardware data",
+        "## Hardware data used by this synthetic sweep",
        "",
        f"- Real GPS capture: {len(gdop)} GDOP samples and {len(tracked)} "
        "tracked-satellite samples over about five minutes.",
@@ -613,10 +613,12 @@ def write_report(
        f"{_fmt(telemetry.horizontal_rms_m)} / "
        f"{_fmt(telemetry.horizontal_p95_m)} / "
        f"{_fmt(telemetry.horizontal_max_m)} m. No surveyed truth was recorded.",
-        "- No real ABS_SAMPLE, REM_CODE_PHASE, TDOP/HDOP, C/N0, pseudorange "
-        "residual, PPS phase/rate/integrator, temperature, or trusted-edge TIC "
-        "samples exist in the repository. Those columns in the companion CSV "
-        "are explicitly synthetic.",
+        "- The older fusion capture used by this sweep has no ABS_SAMPLE, "
+        "REM_CODE_PHASE, TDOP/HDOP, C/N0, pseudorange residual, PPS phase/rate/"
+        "integrator, temperature, or trusted-edge TIC samples. Those columns "
+        "in the companion CSV are explicitly synthetic. Newer PPS status "
+        "captures are analyzed separately by `hardware_replay.py` and are not "
+        "silently mixed into this historical baseline.",
        "",
        "Synthetic timing uses the board-calibration values already encoded "
        "in the PPS tests: TDOP 1.50, GDOP 2.92, clock sigma 15.87 m "
@@ -0,0 +1,113 @@
+from __future__ import annotations
+
+import csv
+import math
+from pathlib import Path
+import tempfile
+import unittest
+
+from pps_python.adaptive_pps import (
+    PROFILES,
+    Profile,
+    Q32,
+    TRACKING_HZ,
+)
+
+from pps_end_to_end_validation.hardware_replay import (
+    UPDATE_PERIOD_S,
+    expand_samples,
+    load_firmware_telemetry,
+    observed_metrics,
+    replay_firmware_telemetry,
+    replay_tuning_sensitivity,
+)
+
+
+def _status_line(index: int) -> str:
+    phase_ns = 140.0 + 15.0 * math.sin(index * 0.7)
+    integrator_ppm = -1.560
+    kp_q46, _, _ = PROFILES[Profile.ROBUST].fixed_coefficients(
+        UPDATE_PERIOD_S
+    )
+    phase_q32 = round(phase_ns * 1.0e-9 * TRACKING_HZ * Q32)
+    proportional_q32 = (phase_q32 * kp_q46) >> 46
+    rate_ppm = (
+        round(integrator_ppm * 1.0e-6 * Q32) + proportional_q32
+    ) / Q32 * 1.0e6
+    raw_bias_m = 700_000.0 - 80.0 * (2.0 * index) + 4.0 * math.sin(index)
+    filtered_bias_m = 700_000.0 - 80.0 * (2.0 * index)
+    return (
+        "[NAV] PPS profile=robust mode=tracking locked=1 "
+        "tdop=1.22 gdop=2.82 clock_sigma=11.24 cn0=42.6/38.4 "
+        f"innovation={raw_bias_m - filtered_bias_m:.2f}m "
+        f"raw_bias={raw_bias_m:.3f}m filtered_bias={filtered_bias_m:.3f}m "
+        "clock_drift=110.000mps bias_drift=-80.000mps predictor=1 "
+        "eskf_alpha=0.05 eskf_v=0.100/0.050/0x00 "
+        "pps_v=0.100/0.080/0x00 ref_svid=23 capture_corr=32.00ns "
+        f"hw_phase={phase_ns:.2f}ns rate_cmd={rate_ppm:.3f}ppm "
+        f"integ={integrator_ppm:.3f}ppm pulse={100 + 2 * index} "
+        f"seq={1000 + 10 * index} status=0x80f"
+    )
+
+
+def _write_capture(path: Path, count: int = 16) -> None:
+    location = (
+        "[LOCATION] source=gps lat=0 lon=0 height=0 "
+        "gdop=2.82 pdop=2.54 hdop=1.81 vdop=1.78 tdop=1.22 "
+        "tracked=6 used=5 velocity_valid=1 velocity_fde=0 "
+        "speed=0.1 velocity_rms=0.08"
+    )
+    with path.open("w", encoding="utf-8", newline="") as output:
+        writer = csv.writer(output, lineterminator="\n")
+        writer.writerow(("host_monotonic_s", "host_unix_s", "uart_line"))
+        for index in range(count):
+            host_s = 2.0 * index
+            writer.writerow((host_s - 0.01, 1000.0 + host_s, location))
+            writer.writerow((host_s, 1000.01 + host_s, _status_line(index)))
+
+
+class HardwareReplayTests(unittest.TestCase):
+    def setUp(self) -> None:
+        self.temporary = tempfile.TemporaryDirectory()
+        self.capture = Path(self.temporary.name) / "capture.csv"
+        _write_capture(self.capture)
+
+    def tearDown(self) -> None:
+        self.temporary.cleanup()
+
+    def test_uart_parser_and_sequence_expansion(self):
+        samples = load_firmware_telemetry(self.capture)
+        self.assertEqual(len(samples), 16)
+        self.assertEqual(samples[-1].time_s, 30.0)
+        self.assertEqual(samples[0].tracked_satellites, 6)
+        self.assertEqual(samples[0].used_satellites, 5)
+        expanded = expand_samples(samples)
+        self.assertEqual(len(expanded), 151)
+        self.assertEqual(sum(interpolated for _, interpolated in expanded), 135)
+
+    def test_fixed_point_pi_and_checkpoint_replay(self):
+        samples = load_firmware_telemetry(self.capture)
+        observed = observed_metrics(samples)
+        self.assertEqual(observed.locked_fraction, 1.0)
+        self.assertLess(observed.pi_rate_reproduction_rms_ppb, 0.6)
+        points, replay = replay_firmware_telemetry(
+            samples, warmup_s=5.0
+        )
+        self.assertEqual(len(points), 151)
+        self.assertEqual(replay.unlocks, 0)
+        self.assertEqual(replay.locked_fraction_after_warmup, 1.0)
+        self.assertTrue(math.isfinite(replay.modeled_edge_centered_rms_ns))
+        self.assertGreater(replay.modeled_edge_centered_rms_ns, 0.0)
+
+    def test_tuning_sensitivity_keeps_candidates_separate(self):
+        samples = load_firmware_telemetry(self.capture)
+        results = replay_tuning_sensitivity(samples, warmup_s=5.0)
+        self.assertEqual(
+            [result.tuning for result in results],
+            ["current", "robust_bias_1_64", "drift_gain_1_2"],
+        )
+        self.assertTrue(all(result.unlocks == 0 for result in results))
+
+
+if __name__ == "__main__":
+    unittest.main()
@@ -404,6 +404,88 @@ class FixedPointAdaptivePps:
    def _phase_q32_to_seconds(value: int) -> float:
        return value / (TRACKING_HZ * Q32)

+    def seed_tracking_state(
+        self,
+        *,
+        time_s: float,
+        profile: Profile,
+        phase_error_s: float,
+        rate_command_ppm: float,
+        integrator_ppm: float,
+        software_error_s: float,
+        software_bias_m: float,
+        software_clock_drift_mps: float,
+        software_previous_measurement_m: float,
+        reference_id: int,
+    ) -> None:
+        """Start a replay from a captured, already-locked board snapshot.
+
+        Normal simulations deliberately start unaligned and exercise coarse
+        acquisition.  Hardware logs, however, are commonly captured after the
+        board has been tracking for minutes.  Replaying such a log from reset
+        introduces an artificial acquisition transient and clears the PI
+        integrator that was present on the board.  This method imports only
+        state that the production diagnostic registers and firmware status
+        expose; subsequent updates still use the normal bit-accurate path.
+
+        The method must be called before any observation has been recorded.
+        It is a model facility and has no firmware/RTL side effect.
+        """
+        finite_values = (
+            time_s,
+            phase_error_s,
+            rate_command_ppm,
+            integrator_ppm,
+            software_error_s,
+            software_bias_m,
+            software_clock_drift_mps,
+            software_previous_measurement_m,
+        )
+        if self.trace.time_s:
+            raise ValueError("tracking state must be seeded before replay")
+        if not all(math.isfinite(value) for value in finite_values):
+            raise ValueError("tracking state values must be finite")
+        if time_s < 0.0:
+            raise ValueError("tracking state time must be non-negative")
+        if profile == Profile.HOLDOVER:
+            raise ValueError("a locked snapshot cannot use holdover profile")
+
+        self.current_time_s = time_s
+        self.raw_tick_remainder = 0.0
+        self.phase_q32 = self._seconds_to_phase_q32(phase_error_s)
+        self.profile = profile
+        self.selector.profile = profile
+        self.selector.candidate = profile
+        self.selector.candidate_updates = 0
+        self.aligned = True
+        self.locked = True
+        self.lock_good_updates = 0
+        self.reference_watchdog_holdover = False
+        self._select_loop_parameters()
+        self.integrator_q32 = self._clamp(
+            round(integrator_ppm * 1.0e-6 * Q32), self.max_slew_q32
+        )
+        self.rate_word_q32 = self._clamp(
+            round(rate_command_ppm * 1.0e-6 * Q32), self.max_slew_q32
+        )
+
+        self.software_error_s = software_error_s
+        self.software_bias_m = software_bias_m
+        self.software_clock_drift_mps = software_clock_drift_mps
+        self.software_previous_measurement_m = (
+            software_previous_measurement_m
+        )
+        self.software_drift_anchor_time_s = time_s
+        self.software_drift_anchor_measurement_m = (
+            software_previous_measurement_m
+        )
+        self.software_drift_initialized = True
+        self.software_updates = max(
+            1, self.parameters.software_settle_updates
+        )
+        self.software_reference_id = reference_id
+        self.last_observation_time_s = time_s
+
    def _apply_profile(self, profile: Profile) -> None:
        self.profile = profile
        self._select_loop_parameters()