Calibration supercharged

.gitignore

@@ -5,3 +5,4 @@ sim_results/
 sim_results_multi/
 tuningTrials/
 # RL_Trials/
+venv/

A0Calibration/A0CalibrationSketch/A0CalibrationSketch.ino

@@ -0,0 +1,152 @@
+// A0CalibrationSketch
+// ────────────────────────────────────────────────────────────
+// Trimmed-down calibration streamer. Continuously outputs
+// "<mm>, <a0_raw>" lines over serial, where <mm> is the
+// position measured by one of the two known sensors (A2, A3)
+// and <a0_raw> is the raw ADC count from the unknown sensor
+// on A0. A companion Python notebook buckets these points
+// into 0.05mm intervals and exports an Excel calibration.
+//
+// Handshake protocol (restartable without re-uploading):
+//   Wake byte : 'S'  Python -> Arduino  (start/restart streaming)
+//   Stop byte : 'X'  Python -> Arduino  (stop streaming, return to idle)
+//
+//   Idle state  : Arduino waits for 'S', ignores all other bytes.
+//   Stream state: Arduino emits data lines, watches for 'X'.
+//                 On 'X' it returns to idle state.
+//
+//   Python connect sequence (works regardless of current Arduino state):
+//     1. Send 'X'             (stops streaming if running; no-op if idle)
+//     2. sleep 200 ms + flush (drain any in-flight data lines)
+//     3. Send 'S'             (Arduino: 1 s settle, then prints #READY)
+//     4. Wait for '#READY'
+//
+//   Data lines: <float_mm>, <int_a0_raw>\n  — no other output ever.
+// ────────────────────────────────────────────────────────────
+
+#include <Arduino.h>
+#include <util/atomic.h>
+
+// ── ADC Interrupt-driven 3-channel read (A2, A3, A0) ─────────
+// Channel index: 0 → A2 (sensor 0), 1 → A3 (sensor 1), 2 → A0 (unknown)
+static const uint8_t adc_mux[3] = {2, 3, 1};
+
+volatile uint16_t adc_result[3] = {0, 0, 0};
+volatile bool     adc_ready[3]  = {false, false, false};
+volatile uint8_t  adc_channel   = 0;
+
+void setupADC() {
+  ADMUX = (1 << REFS0) | adc_mux[0];   // AVCC ref, start on A2
+  ADCSRA = (1 << ADEN) | (1 << ADIE) | (1 << ADPS2);  // /16 prescaler
+  ADCSRA |= (1 << ADSC);
+}
+
+// ── OOR digital inputs ───────────────────────────────────────
+#define OOR_PIN_0  12    // HIGH = out of range, sensor 0 (A2)
+#define OOR_PIN_1  13    // HIGH = out of range, sensor 1 (A3)
+
+volatile bool OOR[2];
+
+ISR(ADC_vect) {
+  uint16_t sample = ADC;
+  uint8_t ch   = adc_channel;
+  uint8_t next = (ch + 1) % 3;
+
+  if (ch < 2) {
+    OOR[ch] = digitalRead(ch == 0 ? OOR_PIN_0 : OOR_PIN_1);
+    if (!OOR[ch]) {
+      adc_result[ch] = sample;
+      adc_ready[ch]  = true;
+    }
+  } else {
+    // A0: no OOR, always store
+    adc_result[2] = sample;
+    adc_ready[2]  = true;
+  }
+
+  ADMUX = (ADMUX & 0xF0) | adc_mux[next];
+  adc_channel = next;
+  ADCSRA |= (1 << ADSC);
+}
+
+// ── ADC → mm linear mappings (raw range: 16–26 mm) ──────────
+// Kept identical to AltSensorTesting.ino so calibration is
+// performed in the same position frame.
+#define adcToMM0(adc) ((float)map(adc, 178, 895, 1600, 2600) / 100.0f)
+#define adcToMM1(adc) ((float)map(adc, 176, 885, 1600, 2600) / 100.0f)
+
+// Mounting offsets so sensor 0 → 0–10 mm, sensor 1 → 10–20 mm
+#define OFFSET_MM0  15.6f
+#define OFFSET_MM1   6.2f
+
+// ── Streaming state ──────────────────────────────────────────
+bool streaming = false;
+
+// Enter idle: wait for the 'S' wake byte (all other bytes ignored).
+// Then settle, clear stale ADC flags, announce #READY, and set streaming.
+// Can be called from both setup() and loop() for restartable sessions.
+void waitForWake() {
+  streaming = false;
+  while (true) {
+    if (Serial.available()) {
+      char c = Serial.read();
+      if (c == 'S') break;
+      // Any other byte (e.g. stray 'X') is silently discarded.
+    }
+  }
+  delay(1000);  // ADC reference settle
+  ATOMIC_BLOCK(ATOMIC_RESTORESTATE) {
+    adc_ready[0] = adc_ready[1] = adc_ready[2] = false;
+  }
+  Serial.println(F("#READY"));
+  streaming = true;
+}
+
+// ═════════════════════════════════════════════════════════════
+void setup() {
+  Serial.begin(2000000);
+  pinMode(OOR_PIN_0, INPUT);
+  pinMode(OOR_PIN_1, INPUT);
+  setupADC();      // ADC runs continuously; emission is gated by streaming flag
+  waitForWake();
+}
+
+void loop() {
+  // Check for stop byte before doing any work.
+  if (Serial.available()) {
+    char c = Serial.read();
+    if (c == 'X') {
+      waitForWake();  // returns only after next 'S' + #READY
+      return;
+    }
+  }
+
+  if (!streaming) return;
+
+  uint16_t val[3];
+  bool ready[3];
+  ATOMIC_BLOCK(ATOMIC_RESTORESTATE) {
+    for (uint8_t i = 0; i < 3; i++) {
+      ready[i]     = adc_ready[i];
+      val[i]       = adc_result[i];
+      adc_ready[i] = false;
+    }
+  }
+
+  if (!ready[0] && !ready[1]) return;
+
+  // Emit one line per in-range sensor sample, paired with the
+  // most recent A0 raw ADC count (val[2] is always fresh).
+  if (ready[0]) {
+    float mm = adcToMM0(val[0]) - OFFSET_MM0;
+    Serial.print(mm, 3);
+    Serial.print(F(", "));
+    Serial.println(val[2]);
+  }
+  if (ready[1]) {
+    float mm = adcToMM1(val[1]) - OFFSET_MM1;
+    Serial.print(mm, 3);
+    Serial.print(F(", "));
+    Serial.println(val[2]);
+  }
+}

A0Calibration/calibrate_a0.ipynb

@@ -0,0 +1,483 @@
+{
+ "cells": [
+  {
+   "cell_type": "markdown",
+   "metadata": {},
+   "source": [
+    "# A0 Sensor Calibration\n",
+    "\n",
+    "Streams `mm, a0_raw` lines from the `A0CalibrationSketch` Arduino sketch, buckets them into 0.05 mm intervals (±0.02 mm acceptance window), and exports a calibration table to `data/` as a timestamped Excel file.\n",
+    "\n",
+    "**Workflow**\n",
+    "1. Upload `A0CalibrationSketch/A0CalibrationSketch.ino` to the Arduino.\n",
+    "2. Run the **Config** and **Connect** cells below.\n",
+    "3. Run the **Collect** cell and sweep the target slowly through the full 0–20 mm range. The cell terminates automatically once every bucket has ≥50 samples, or press **Stop Collection** to halt early.\n",
+    "4. Run the **Export** cell.\n"
+   ]
+  },
+  {
+   "cell_type": "code",
+   "execution_count": 4,
+   "id": "83a5e59e",
+   "metadata": {},
+   "outputs": [
+    {
+     "name": "stdout",
+     "output_type": "stream",
+     "text": [
+      "401 buckets from 0.0 to 20.0 mm (step 0.05 mm)\n",
+      "Acceptance window: +/-0.02 mm from each bucket center\n",
+      "Target: >= 50 samples per bucket\n"
+     ]
+    }
+   ],
+   "source": [
+    "# === Config ===\n",
+    "SERIAL_PORT   = None       # e.g. '/dev/cu.usbmodem14101'; None -> auto-detect\n",
+    "BAUD_RATE     = 115200\n",
+    "\n",
+    "MM_MIN        = 0.0\n",
+    "MM_MAX        = 20.0\n",
+    "BUCKET_STEP   = 0.05       # bucket spacing (mm)\n",
+    "BUCKET_WINDOW = 0.02       # accept samples within +/- WINDOW of bucket center\n",
+    "MIN_SAMPLES   = 50         # each bucket must reach this count to auto-stop\n",
+    "\n",
+    "from pathlib import Path\n",
+    "DATA_DIR = Path('data')\n",
+    "DATA_DIR.mkdir(exist_ok=True)\n",
+    "\n",
+    "import numpy as np\n",
+    "\n",
+    "N_BUCKETS      = int(round((MM_MAX - MM_MIN) / BUCKET_STEP)) + 1\n",
+    "bucket_centers = np.round(MM_MIN + np.arange(N_BUCKETS) * BUCKET_STEP, 4)\n",
+    "\n",
+    "print(f\"{N_BUCKETS} buckets from {MM_MIN} to {MM_MAX} mm (step {BUCKET_STEP} mm)\")\n",
+    "print(f\"Acceptance window: +/-{BUCKET_WINDOW} mm from each bucket center\")\n",
+    "print(f\"Target: >= {MIN_SAMPLES} samples per bucket\")\n"
+   ]
+  },
+  {
+   "cell_type": "markdown",
+   "id": "7b88a837",
+   "metadata": {},
+   "source": [
+    "## 1. Connect to Arduino"
+   ]
+  },
+  {
+   "cell_type": "code",
+   "execution_count": 5,
+   "id": "bee575ca",
+   "metadata": {},
+   "outputs": [
+    {
+     "name": "stdout",
+     "output_type": "stream",
+     "text": [
+      "Opening /dev/cu.usbmodem11301 @ 115200...\n",
+      "Sending wake signal...\n",
+      "Waiting for #READY marker...\n",
+      "Arduino ready - streaming.\n"
+     ]
+    }
+   ],
+   "source": [
+    "import serial\n",
+    "import serial.tools.list_ports\n",
+    "import time\n",
+    "\n",
+    "def find_port():\n",
+    "    if SERIAL_PORT is not None:\n",
+    "        return SERIAL_PORT\n",
+    "    ports = list(serial.tools.list_ports.comports())\n",
+    "    for p in ports:\n",
+    "        dev  = p.device\n",
+    "        desc = (p.description or '').lower()\n",
+    "        if ('usbmodem' in dev or 'usbserial' in dev.lower()\n",
+    "                or 'arduino' in desc or 'wch' in desc):\n",
+    "            return dev\n",
+    "    if ports:\n",
+    "        return ports[0].device\n",
+    "    raise RuntimeError(\"No serial ports found. Set SERIAL_PORT manually.\")\n",
+    "\n",
+    "port = find_port()\n",
+    "print(f\"Opening {port} @ {BAUD_RATE}...\")\n",
+    "\n",
+    "# Close any previously-held handle if this cell is re-run.\n",
+    "try:\n",
+    "    if ser.is_open:\n",
+    "        ser.close()\n",
+    "except NameError:\n",
+    "    pass\n",
+    "\n",
+    "ser = serial.Serial(port, BAUD_RATE, timeout=0.1)\n",
+    "\n",
+    "# Opening the port may or may not reset the board.\n",
+    "# Either way, the Arduino is in idle state (waiting for 'S') after boot.\n",
+    "# Wait for reset/boot to finish, then flush anything printed before we opened.\n",
+    "time.sleep(3.0)\n",
+    "ser.reset_input_buffer()\n",
+    "\n",
+    "# Send 'X' first: stops any ongoing stream if the Arduino was already running.\n",
+    "# If it's in idle state, 'X' is silently ignored.\n",
+    "ser.write(b'X')\n",
+    "time.sleep(0.2)\n",
+    "ser.reset_input_buffer()\n",
+    "\n",
+    "# Send the wake byte. Arduino will settle for 1 s then print #READY.\n",
+    "print(\"Sending wake signal...\")\n",
+    "ser.write(b'S')\n",
+    "\n",
+    "print(\"Waiting for #READY marker...\")\n",
+    "deadline   = time.time() + 15.0\n",
+    "seen_ready = False\n",
+    "while time.time() < deadline:\n",
+    "    raw = ser.readline()\n",
+    "    if not raw:\n",
+    "        continue\n",
+    "    if raw.strip() == b'#READY':\n",
+    "        seen_ready = True\n",
+    "        break\n",
+    "\n",
+    "if not seen_ready:\n",
+    "    raise RuntimeError(\n",
+    "        \"Did not receive #READY within 15s. \"\n",
+    "        \"Check sketch is uploaded and SERIAL_PORT is correct.\"\n",
+    "    )\n",
+    "\n",
+    "# Discard one line to ensure we start reading on a clean boundary.\n",
+    "_ = ser.readline()\n",
+    "print(\"Arduino ready - streaming.\")\n"
+   ]
+  },
+  {
+   "cell_type": "markdown",
+   "id": "f4955b1c",
+   "metadata": {},
+   "source": [
+    "## 2. Collect calibration data\n",
+    "\n",
+    "Run this cell and slowly sweep the target through the full 0–20 mm range. The cell drains the serial stream in a background thread, buckets each valid sample, and updates the plot every ~0.3 s.\n",
+    "\n",
+    "Press **Stop Collection** to halt early, or let it run until every bucket has reached the target.\n"
+   ]
+  },
+  {
+   "cell_type": "code",
+   "execution_count": 6,
+   "id": "1207881e",
+   "metadata": {},
+   "outputs": [
+    {
+     "data": {
+      "application/vnd.jupyter.widget-view+json": {
+       "model_id": "0aa7a77335254ed68cf8461be35468c7",
+       "version_major": 2,
+       "version_minor": 0
+      },
+      "text/plain": [
+       "VBox(children=(HBox(children=(Button(button_style='danger', description='Stop Collection', icon='stop', style=…"
+      ]
+     },
+     "metadata": {},
+     "output_type": "display_data"
+    },
+    {
+     "ename": "CancelledError",
+     "evalue": "",
+     "output_type": "error",
+     "traceback": [
+      "\u001b[31m---------------------------------------------------------------------------\u001b[39m",
+      "\u001b[31mCancelledError\u001b[39m                            Traceback (most recent call last)",
+      "\u001b[36mCell\u001b[39m\u001b[36m \u001b[39m\u001b[32mIn[6]\u001b[39m\u001b[32m, line 174\u001b[39m\n\u001b[32m    170\u001b[39m             \u001b[38;5;28;01mbreak\u001b[39;00m\n\u001b[32m    171\u001b[39m \n\u001b[32m    172\u001b[39m         \u001b[38;5;28;01mawait\u001b[39;00m asyncio.sleep(\u001b[32m0.05\u001b[39m)\n\u001b[32m    173\u001b[39m \n\u001b[32m--> \u001b[39m\u001b[32m174\u001b[39m \u001b[38;5;28;01mawait\u001b[39;00m collect()\n\u001b[32m    175\u001b[39m \n\u001b[32m    176\u001b[39m \u001b[38;5;66;03m# Tell the Arduino to stop streaming and return to idle,\u001b[39;00m\n\u001b[32m    177\u001b[39m \u001b[38;5;66;03m# so the connect cell can restart without re-uploading the sketch.\u001b[39;00m\n",
+      "\u001b[36mCell\u001b[39m\u001b[36m \u001b[39m\u001b[32mIn[6]\u001b[39m\u001b[32m, line 172\u001b[39m, in \u001b[36mcollect\u001b[39m\u001b[34m()\u001b[39m\n\u001b[32m    168\u001b[39m         \u001b[38;5;28;01mif\u001b[39;00m filled == N_BUCKETS:\n\u001b[32m    169\u001b[39m             status_label.value += \u001b[33m'  -- target reached'\u001b[39m\n\u001b[32m    170\u001b[39m             \u001b[38;5;28;01mbreak\u001b[39;00m\n\u001b[32m    171\u001b[39m \n\u001b[32m--> \u001b[39m\u001b[32m172\u001b[39m         \u001b[38;5;28;01mawait\u001b[39;00m asyncio.sleep(\u001b[32m0.05\u001b[39m)\n",
+      "\u001b[36mFile \u001b[39m\u001b[32m/Library/Frameworks/Python.framework/Versions/3.13/lib/python3.13/asyncio/tasks.py:718\u001b[39m, in \u001b[36msleep\u001b[39m\u001b[34m(delay, result)\u001b[39m\n\u001b[32m    714\u001b[39m h = loop.call_later(delay,\n\u001b[32m    715\u001b[39m                     futures._set_result_unless_cancelled,\n\u001b[32m    716\u001b[39m                     future, result)\n\u001b[32m    717\u001b[39m \u001b[38;5;28;01mtry\u001b[39;00m:\n\u001b[32m--> \u001b[39m\u001b[32m718\u001b[39m     \u001b[38;5;28;01mreturn\u001b[39;00m \u001b[38;5;28;01mawait\u001b[39;00m future\n\u001b[32m    719\u001b[39m \u001b[38;5;28;01mfinally\u001b[39;00m:\n\u001b[32m    720\u001b[39m     h.cancel()\n",
+      "\u001b[31mCancelledError\u001b[39m: "
+     ]
+    }
+   ],
+   "source": [
+    "import re\n",
+    "import queue\n",
+    "import threading\n",
+    "import asyncio\n",
+    "import time\n",
+    "import matplotlib.pyplot as plt\n",
+    "import ipywidgets as widgets\n",
+    "from IPython.display import display, clear_output\n",
+    "\n",
+    "# === Bucket state (reset on each run of this cell) ===\n",
+    "counts = np.zeros(N_BUCKETS, dtype=np.int64)\n",
+    "means  = np.zeros(N_BUCKETS, dtype=np.float64)\n",
+    "\n",
+    "# Matches \"<float>, <int>\" with optional leading sign and whitespace.\n",
+    "LINE_RE = re.compile(r'^\\s*(-?\\d+\\.?\\d*)\\s*,\\s*(\\d+)\\s*$')\n",
+    "\n",
+    "def update_bucket(mm, adc):\n",
+    "    idx = int(round((mm - MM_MIN) / BUCKET_STEP))\n",
+    "    if idx < 0 or idx >= N_BUCKETS:\n",
+    "        return False\n",
+    "    if abs(mm - bucket_centers[idx]) > BUCKET_WINDOW + 1e-9:\n",
+    "        return False  # falls into the gap between bucket windows\n",
+    "    counts[idx] += 1\n",
+    "    # Welford-style incremental mean (numerically stable, no accumulator overflow)\n",
+    "    means[idx] += (adc - means[idx]) / counts[idx]\n",
+    "    return True\n",
+    "\n",
+    "# === Serial reader thread ===\n",
+    "# If this cell is re-run, stop the previous reader first so we don't end up\n",
+    "# with two threads racing on ser.readline().\n",
+    "try:\n",
+    "    _reader_stop.set()\n",
+    "    _reader_thread.join(timeout=1.0)\n",
+    "except NameError:\n",
+    "    pass\n",
+    "\n",
+    "_reader_stop = threading.Event()\n",
+    "line_queue   = queue.Queue()\n",
+    "\n",
+    "def _reader_loop(stop_ev, q, s):\n",
+    "    while not stop_ev.is_set():\n",
+    "        try:\n",
+    "            raw = s.readline()   # returns after timeout=0.1s if no data\n",
+    "        except Exception:\n",
+    "            break\n",
+    "        if raw:\n",
+    "            q.put(raw)\n",
+    "\n",
+    "_reader_thread = threading.Thread(\n",
+    "    target=_reader_loop, args=(_reader_stop, line_queue, ser), daemon=True,\n",
+    ")\n",
+    "_reader_thread.start()\n",
+    "\n",
+    "# === UI widgets ===\n",
+    "stop_button = widgets.Button(\n",
+    "    description='Stop Collection', button_style='danger', icon='stop',\n",
+    ")\n",
+    "progress = widgets.IntProgress(\n",
+    "    min=0, max=N_BUCKETS, value=0,\n",
+    "    description='Buckets @target:', bar_style='info',\n",
+    "    style={'description_width': 'initial'},\n",
+    "    layout=widgets.Layout(width='500px'),\n",
+    ")\n",
+    "status_label = widgets.Label(value='Starting...')\n",
+    "plot_out     = widgets.Output()\n",
+    "\n",
+    "stop_requested = False\n",
+    "def _on_stop(_b):\n",
+    "    global stop_requested\n",
+    "    stop_requested = True\n",
+    "    stop_button.description = 'Stopping...'\n",
+    "    stop_button.disabled    = True\n",
+    "stop_button.on_click(_on_stop)\n",
+    "\n",
+    "display(widgets.VBox([\n",
+    "    widgets.HBox([stop_button, progress]),\n",
+    "    status_label,\n",
+    "    plot_out,\n",
+    "]))\n",
+    "\n",
+    "# === Live plot ===\n",
+    "plt.ioff()\n",
+    "fig, (ax1, ax2) = plt.subplots(2, 1, figsize=(10, 6), sharex=True)\n",
+    "plt.close(fig)  # prevent implicit display; we manage display manually\n",
+    "\n",
+    "def _draw():\n",
+    "    ax1.clear(); ax2.clear()\n",
+    "    filled = counts > 0\n",
+    "    if filled.any():\n",
+    "        ax1.plot(bucket_centers[filled], means[filled], 'b.-', markersize=3)\n",
+    "    ax1.set_ylabel('Avg A0 ADC')\n",
+    "    ax1.set_title('Calibration curve (filled buckets)')\n",
+    "    ax1.grid(True, alpha=0.3)\n",
+    "\n",
+    "    colors = [\n",
+    "        '#2ecc71' if c >= MIN_SAMPLES\n",
+    "        else '#f39c12' if c > 0\n",
+    "        else '#e74c3c'\n",
+    "        for c in counts\n",
+    "    ]\n",
+    "    ax2.bar(bucket_centers, counts, width=BUCKET_STEP * 0.9, color=colors)\n",
+    "    ax2.axhline(\n",
+    "        MIN_SAMPLES, color='red', linestyle='--', linewidth=1,\n",
+    "        label=f'target = {MIN_SAMPLES}',\n",
+    "    )\n",
+    "    ax2.set_xlabel('Position (mm)')\n",
+    "    ax2.set_ylabel('Sample count')\n",
+    "    ax2.set_title('Bucket fill progress  (green = done, orange = partial, red = empty)')\n",
+    "    ax2.legend(loc='upper right', fontsize=8)\n",
+    "    ax2.grid(True, alpha=0.3)\n",
+    "\n",
+    "    fig.tight_layout()\n",
+    "    with plot_out:\n",
+    "        clear_output(wait=True)\n",
+    "        display(fig)\n",
+    "\n",
+    "_draw()\n",
+    "\n",
+    "# === Collection loop ===\n",
+    "total_parsed    = 0\n",
+    "total_bucketed  = 0\n",
+    "total_malformed = 0\n",
+    "last_draw       = time.monotonic()\n",
+    "DRAW_INTERVAL   = 0.3  # seconds\n",
+    "\n",
+    "async def collect():\n",
+    "    global total_parsed, total_bucketed, total_malformed, last_draw\n",
+    "\n",
+    "    while not stop_requested:\n",
+    "        # Drain whatever came in since last tick.\n",
+    "        try:\n",
+    "            while True:\n",
+    "                raw = line_queue.get_nowait()\n",
+    "                try:\n",
+    "                    txt = raw.decode('ascii', errors='replace').strip()\n",
+    "                except Exception:\n",
+    "                    total_malformed += 1\n",
+    "                    continue\n",
+    "                if not txt or txt.startswith('#'):\n",
+    "                    continue  # stray marker or blank line\n",
+    "                m = LINE_RE.match(txt)\n",
+    "                if not m:\n",
+    "                    total_malformed += 1\n",
+    "                    continue\n",
+    "                total_parsed += 1\n",
+    "                mm  = float(m.group(1))\n",
+    "                adc = int(m.group(2))\n",
+    "                if update_bucket(mm, adc):\n",
+    "                    total_bucketed += 1\n",
+    "        except queue.Empty:\n",
+    "            pass\n",
+    "\n",
+    "        filled = int(np.sum(counts >= MIN_SAMPLES))\n",
+    "\n",
+    "        now = time.monotonic()\n",
+    "        if now - last_draw >= DRAW_INTERVAL:\n",
+    "            last_draw = now\n",
+    "            progress.value = filled\n",
+    "            status_label.value = (\n",
+    "                f\"filled={filled}/{N_BUCKETS}  \"\n",
+    "                f\"min_count={int(counts.min())}  \"\n",
+    "                f\"parsed={total_parsed}  \"\n",
+    "                f\"bucketed={total_bucketed}  \"\n",
+    "                f\"malformed={total_malformed}\"\n",
+    "            )\n",
+    "            _draw()\n",
+    "\n",
+    "        if filled == N_BUCKETS:\n",
+    "            status_label.value += '  -- target reached'\n",
+    "            break\n",
+    "\n",
+    "        await asyncio.sleep(0.05)\n",
+    "\n",
+    "await collect()\n",
+    "\n",
+    "# Tell the Arduino to stop streaming and return to idle,\n",
+    "# so the connect cell can restart without re-uploading the sketch.\n",
+    "try:\n",
+    "    ser.write(b'X')\n",
+    "    time.sleep(0.1)\n",
+    "    ser.reset_input_buffer()\n",
+    "except Exception:\n",
+    "    pass\n",
+    "\n",
+    "# Clean shutdown of the reader thread.\n",
+    "_reader_stop.set()\n",
+    "\n",
+    "_draw()\n",
+    "filled_final = int(np.sum(counts >= MIN_SAMPLES))\n",
+    "status_label.value = (\n",
+    "    f\"DONE. filled={filled_final}/{N_BUCKETS}  \"\n",
+    "    f\"parsded={total_parsed}  bucketed={total_bucketed}  malformed={total_malformed}\"\n",
+    ")\n",
+    "stop_button.description = 'Stopped'\n"
+   ]
+  },
+  {
+   "cell_type": "markdown",
+   "metadata": {},
+   "source": [
+    "## 3. Export to Excel"
+   ]
+  },
+  {
+   "cell_type": "code",
+   "execution_count": null,
+   "metadata": {},
+   "outputs": [],
+   "source": [
+    "from datetime import datetime\n",
+    "import pandas as pd\n",
+    "\n",
+    "ts       = datetime.now().strftime('%Y%m%d_%H%M%S')\n",
+    "out_path = DATA_DIR / f'a0_calibration_{ts}.xlsx'\n",
+    "\n",
+    "has_data = counts > 0\n",
+    "df = pd.DataFrame({\n",
+    "    'mm_val':  bucket_centers[has_data],\n",
+    "    'avg_adc': np.round(means[has_data], 3),\n",
+    "})\n",
+    "\n",
+    "df.to_excel(out_path, index=False)\n",
+    "print(f\"Exported {len(df)} rows -> {out_path.resolve()}\")\n",
+    "\n",
+    "short = (counts > 0) & (counts < MIN_SAMPLES)\n",
+    "empty = counts == 0\n",
+    "if short.any():\n",
+    "    print(f\"  Note: {int(short.sum())} buckets have data but < {MIN_SAMPLES} samples.\")\n",
+    "if empty.any():\n",
+    "    print(f\"  Note: {int(empty.sum())} buckets had no data and are omitted from the export.\")\n",
+    "\n",
+    "df.head()\n"
+   ]
+  },
+  {
+   "cell_type": "markdown",
+   "metadata": {},
+   "source": [
+    "## 4. Cleanup  (optional — run when done)"
+   ]
+  },
+  {
+   "cell_type": "code",
+   "execution_count": null,
+   "metadata": {},
+   "outputs": [],
+   "source": [
+    "try:\n",
+    "    _reader_stop.set()\n",
+    "    _reader_thread.join(timeout=1.0)\n",
+    "except NameError:\n",
+    "    pass\n",
+    "\n",
+    "try:\n",
+    "    if ser.is_open:\n",
+    "        ser.close()\n",
+    "        print(\"Serial port closed.\")\n",
+    "except NameError:\n",
+    "    pass\n"
+   ]
+  }
+ ],
+ "metadata": {
+  "kernelspec": {
+   "display_name": "venv",
+   "language": "python",
+   "name": "python3"
+  },
+  "language_info": {
+   "codemirror_mode": {
+    "name": "ipython",
+    "version": 3
+   },
+   "file_extension": ".py",
+   "mimetype": "text/x-python",
+   "name": "python",
+   "nbconvert_exporter": "python",
+   "pygments_lexer": "ipython3",
+   "version": "3.13.7"
+  }
+ },
+ "nbformat": 4,
+ "nbformat_minor": 5
+}

A0Calibration/calibrate_a0.py

@@ -0,0 +1,447 @@
+#!/usr/bin/env python3
+"""
+A0 Calibration — standalone tkinter GUI
+Usage:  python calibrate_a0.py
+Deps:   pyserial  numpy  pandas  openpyxl  matplotlib
+"""
+
+import re
+import time
+import threading
+from datetime import datetime
+from pathlib import Path
+
+import numpy as np
+import tkinter as tk
+from tkinter import ttk, messagebox
+import matplotlib
+matplotlib.use('TkAgg')
+from matplotlib.figure import Figure
+from matplotlib.backends.backend_tkagg import FigureCanvasTkAgg
+import serial
+import serial.tools.list_ports
+import pandas as pd
+
+# ── Configuration ─────────────────────────────────────────────
+BAUD_RATE        = 2_000_000
+MM_MIN           = 0.0
+MM_MAX           = 20.0
+BUCKET_STEP      = 0.05
+BUCKET_WINDOW    = 0.02
+MIN_SAMPLES      = 50
+DATA_DIR         = Path(__file__).parent / 'data'
+DRAW_INTERVAL_MS = 300      # GUI redraw period — worker is never throttled by this
+
+DATA_DIR.mkdir(exist_ok=True)
+N_BUCKETS      = int(round((MM_MAX - MM_MIN) / BUCKET_STEP)) + 1
+bucket_centers = np.round(MM_MIN + np.arange(N_BUCKETS) * BUCKET_STEP, 4)
+
+# Bytes regex: avoids decode overhead on every line in the hot path
+LINE_RE = re.compile(rb'^\s*(-?\d+\.?\d*)\s*,\s*(\d+)\s*$')
+
+
+class CalibrationApp:
+
+    def __init__(self, root: tk.Tk):
+        self.root = root
+        self.root.title('A0 Sensor Calibration')
+        self.root.minsize(900, 650)
+
+        # ── Shared bucket state (worker writes, GUI reads snapshots) ──
+        self.counts    = np.zeros(N_BUCKETS, dtype=np.int64)
+        self.means     = np.zeros(N_BUCKETS, dtype=np.float64)
+        self.data_lock = threading.Lock()
+
+        # ── Display stats: written by worker, read by GUI ──
+        self._stat_parsed    = 0
+        self._stat_bucketed  = 0
+        self._stat_malformed = 0
+        self._stats_lock     = threading.Lock()
+
+        # ── Thread / connection state ──
+        self.ser           = None
+        self.worker_thread = None
+        self.worker_stop   = threading.Event()
+        self.collecting    = False
+
+        self._build_ui()
+        self._refresh_ports()
+        self._schedule_draw()
+
+    # ── UI construction ───────────────────────────────────────
+
+    def _build_ui(self):
+        # Connection bar
+        top = ttk.Frame(self.root, padding=(6, 6, 6, 2))
+        top.pack(fill='x')
+
+        ttk.Label(top, text='Port:').pack(side='left')
+        self.port_var = tk.StringVar()
+        self.port_cb  = ttk.Combobox(top, textvariable=self.port_var,
+                                     width=30, state='readonly')
+        self.port_cb.pack(side='left', padx=(4, 6))
+        ttk.Button(top, text='↺', width=3,
+                   command=self._refresh_ports).pack(side='left', padx=2)
+        self.conn_btn = ttk.Button(top, text='Connect',
+                                   command=self._toggle_connect)
+        self.conn_btn.pack(side='left', padx=2)
+        self.conn_label = ttk.Label(top, text='● Disconnected',
+                                    foreground='#888')
+        self.conn_label.pack(side='left', padx=8)
+
+        # Control bar
+        ctrl = ttk.Frame(self.root, padding=(6, 2, 6, 2))
+        ctrl.pack(fill='x')
+
+        self.start_btn = ttk.Button(ctrl, text='Start Collection',
+                                    command=self._start, state='disabled')
+        self.start_btn.pack(side='left', padx=2)
+        self.stop_btn = ttk.Button(ctrl, text='Stop Collection',
+                                   command=self._stop, state='disabled')
+        self.stop_btn.pack(side='left', padx=2)
+        ttk.Button(ctrl, text='Export Excel',
+                   command=self._export).pack(side='left', padx=(14, 2))
+
+        ttk.Separator(ctrl, orient='vertical').pack(side='left',
+                                                    fill='y', padx=8)
+
+        self.progress_var = tk.IntVar(value=0)
+        self.progress_bar = ttk.Progressbar(ctrl, variable=self.progress_var,
+                                            maximum=N_BUCKETS, length=260)
+        self.progress_bar.pack(side='left')
+        self.progress_lbl = ttk.Label(ctrl, text=f'  0 / {N_BUCKETS} buckets')
+        self.progress_lbl.pack(side='left')
+
+        # Stats bar
+        sbar = ttk.Frame(self.root, padding=(6, 0, 6, 2))
+        sbar.pack(fill='x')
+        self.stats_lbl = ttk.Label(sbar,
+                                   text='parsed=0   bucketed=0   malformed=0',
+                                   foreground='#555')
+        self.stats_lbl.pack(side='left')
+
+        # Matplotlib canvas
+        self.fig = Figure(tight_layout=True)
+        self.ax1 = self.fig.add_subplot(2, 1, 1)
+        self.ax2 = self.fig.add_subplot(2, 1, 2, sharex=self.ax1)
+        
+        self.ax1.set_ylabel('Avg A0 ADC')
+        self.ax1.set_title('Calibration curve')
+        self.ax1.grid(True, alpha=0.3)
+
+        self.ax2.set_xlabel('Position (mm)')
+        self.ax2.set_ylabel('Sample count')
+        self.ax2.set_title(
+            'Bucket fill progress (green = done, orange = partial, red = empty)')
+        self.ax2.axhline(MIN_SAMPLES, color='red', linestyle='--',
+                         linewidth=1, label=f'target = {MIN_SAMPLES}')
+        self.ax2.legend(fontsize=8, loc='upper right')
+        self.ax2.grid(True, alpha=0.3)
+
+        # Create empty line and bar artists to update later
+        self.line, = self.ax1.plot([], [], 'b.-', markersize=3)
+        self.bars = self.ax2.bar(bucket_centers, np.zeros(N_BUCKETS), width=BUCKET_STEP * 0.9)
+
+        self.canvas = FigureCanvasTkAgg(self.fig, master=self.root)
+        self.canvas.get_tk_widget().pack(fill='both', expand=True,
+                                         padx=6, pady=(2, 6))
+
+    # ── Port management ───────────────────────────────────────
+
+    def _refresh_ports(self):
+        ports = list(serial.tools.list_ports.comports())
+        self.port_cb['values'] = [p.device for p in ports]
+        if not ports:
+            return
+        for p in ports:
+            d = (p.description or '').lower()
+            if ('usbmodem' in p.device or 'usbserial' in p.device.lower()
+                    or 'arduino' in d or 'wch' in d):
+                self.port_var.set(p.device)
+                return
+        if not self.port_var.get():
+            self.port_var.set(ports[0].device)
+
+    # ── Connection ────────────────────────────────────────────
+
+    def _toggle_connect(self):
+        if self.ser and self.ser.is_open:
+            self._disconnect()
+        else:
+            self._connect()
+
+    def _connect(self):
+        port = self.port_var.get()
+        if not port:
+            messagebox.showerror('No port', 'Select a serial port first.')
+            return
+        try:
+            # timeout=0.05: readline() returns within 50 ms when no data,
+            # so the worker's stop-event check is always responsive.
+            self.ser = serial.Serial(port, BAUD_RATE, timeout=0.05)
+        except serial.SerialException as e:
+            messagebox.showerror('Connect failed', str(e))
+            return
+        self.conn_btn.config(state='disabled')
+        self.conn_label.config(text='⏳ Connecting…', foreground='orange')
+        threading.Thread(target=self._handshake, daemon=True).start()
+
+    def _handshake(self):
+        """Runs in a daemon thread so the GUI stays responsive during waits."""
+        try:
+            time.sleep(3.0)             # cover Arduino reset/boot
+            self.ser.reset_input_buffer()
+            self.ser.write(b'X')        # stop stream if already running
+            time.sleep(0.2)
+            self.ser.reset_input_buffer()
+            self.ser.write(b'S')        # send wake byte
+
+            deadline = time.time() + 15.0
+            while time.time() < deadline:
+                raw = self.ser.readline()
+                if raw.strip() == b'#READY':
+                    self.ser.readline()  # discard potential partial first line
+                    self.root.after(0, self._on_connected)
+                    return
+            self.root.after(0, lambda: self._on_connect_failed(
+                'Did not receive #READY within 15 s.\n'
+                'Check sketch upload and baud rate.'))
+        except Exception as e:
+            self.root.after(0, lambda err=str(e): self._on_connect_failed(err))
+
+    def _on_connected(self):
+        self.conn_label.config(text='● Connected', foreground='green')
+        self.conn_btn.config(text='Disconnect', state='normal')
+        self.start_btn.config(state='normal')
+
+    def _on_connect_failed(self, msg):
+        messagebox.showerror('Connection failed', msg)
+        try:
+            self.ser.close()
+        except Exception:
+            pass
+        self.ser = None
+        self.conn_label.config(text='● Disconnected', foreground='#888')
+        self.conn_btn.config(text='Connect', state='normal')
+
+    def _disconnect(self):
+        self._stop()
+        try:
+            if self.ser and self.ser.is_open:
+                self.ser.write(b'X')
+                self.ser.close()
+        except Exception:
+            pass
+        self.ser = None
+        self.conn_label.config(text='● Disconnected', foreground='#888')
+        self.conn_btn.config(text='Connect', state='normal')
+        self.start_btn.config(state='disabled')
+        self.stop_btn.config(state='disabled')
+
+    # ── Collection control ────────────────────────────────────
+
+    def _start(self):
+        if self.collecting:
+            return
+        with self.data_lock:
+            self.counts[:] = 0
+            self.means[:]  = 0.0
+        with self._stats_lock:
+            self._stat_parsed = self._stat_bucketed = self._stat_malformed = 0
+
+        self.collecting = True
+        self.worker_stop.clear()
+        self.worker_thread = threading.Thread(
+            target=self._worker, daemon=True, name='serial-worker')
+        self.worker_thread.start()
+
+        self.start_btn.config(state='disabled')
+        self.stop_btn.config(state='normal')
+
+    def _stop(self):
+        if not self.collecting:
+            return
+        self.collecting = False
+        self.worker_stop.set()
+        if self.worker_thread:
+            self.worker_thread.join(timeout=1.0)
+        self.start_btn.config(
+            state='normal' if (self.ser and self.ser.is_open) else 'disabled')
+        self.stop_btn.config(state='disabled')
+
+    def _auto_complete(self):
+        """Called from worker via root.after — runs on the GUI thread."""
+        self._stop()
+        messagebox.showinfo(
+            'Collection complete',
+            f'All {N_BUCKETS} buckets reached ≥{MIN_SAMPLES} samples.\n'
+            'Click Export Excel to save.')
+
+    # ── Serial worker ─────────────────────────────────────────
+    #
+    # Design priorities:
+    #   1. Never miss a byte — reads everything in the OS buffer each wake
+    #   2. Never wait on the GUI — lock hold-time is a single array update
+    #   3. Auto-complete in O(1) — tracks filled count incrementally
+    #
+    def _worker(self):
+        ser      = self.ser
+        stop     = self.worker_stop
+        counts   = self.counts
+        means    = self.means
+        lock     = self.data_lock
+        centers  = bucket_centers
+
+        parsed = bucketed = malformed = filled_count = 0
+        buf    = bytearray()
+        STAT_EVERY = 500    # flush display stats every N parsed lines
+
+        while not stop.is_set():
+            waiting = ser.in_waiting
+            if waiting:
+                try:
+                    buf += ser.read(waiting)    # single syscall for all bytes
+                except serial.SerialException:
+                    break
+
+                # Process every complete line accumulated in the buffer
+                while b'\n' in buf:
+                    line, buf = buf.split(b'\n', 1)
+                    line = line.strip()
+                    if not line or line[0:1] == b'#':
+                        continue
+
+                    m = LINE_RE.match(line)
+                    if not m:
+                        malformed += 1
+                        continue
+
+                    parsed += 1
+                    mm  = float(m.group(1))
+                    adc = int(m.group(2))
+                    idx = int(round((mm - MM_MIN) / BUCKET_STEP))
+
+                    if (0 <= idx < N_BUCKETS
+                            and abs(mm - centers[idx]) <= BUCKET_WINDOW + 1e-9):
+                        with lock:
+                            counts[idx] += 1
+                            means[idx] += (adc - means[idx]) / counts[idx]
+                            just_filled = (counts[idx] == MIN_SAMPLES)
+
+                        if just_filled:
+                            filled_count += 1
+                            if filled_count == N_BUCKETS:
+                                # Flush final stats then signal the GUI
+                                with self._stats_lock:
+                                    self._stat_parsed    = parsed
+                                    self._stat_bucketed  = bucketed + 1
+                                    self._stat_malformed = malformed
+                                self.root.after(0, self._auto_complete)
+                                return
+                        bucketed += 1
+
+                    if parsed % STAT_EVERY == 0:
+                        with self._stats_lock:
+                            self._stat_parsed    = parsed
+                            self._stat_bucketed  = bucketed
+                            self._stat_malformed = malformed
+            else:
+                # Serial quiet — yield briefly so stop_event can be noticed
+                time.sleep(0.0005)
+
+        # Final stats flush on manual stop
+        with self._stats_lock:
+            self._stat_parsed    = parsed
+            self._stat_bucketed  = bucketed
+            self._stat_malformed = malformed
+
+    # ── GUI draw (runs on main thread via root.after) ─────────
+
+    def _schedule_draw(self):
+        self._draw()
+        self.root.after(DRAW_INTERVAL_MS, self._schedule_draw)
+
+    def _draw(self):
+        with self.data_lock:
+            counts = self.counts.copy()
+            means  = self.means.copy()
+        with self._stats_lock:
+            parsed    = self._stat_parsed
+            bucketed  = self._stat_bucketed
+            malformed = self._stat_malformed
+
+        filled = int(np.sum(counts >= MIN_SAMPLES))
+        self.progress_var.set(filled)
+        self.progress_lbl.config(text=f'  {filled} / {N_BUCKETS} buckets')
+        self.stats_lbl.config(
+            text=f'parsed={parsed}   bucketed={bucketed}   malformed={malformed}')
+
+        # --- NEW: Update existing artists instead of clearing axes ---
+        has = counts > 0
+        if has.any():
+            self.line.set_data(bucket_centers[has], means[has])
+            self.ax1.relim()           # Recalculate limits
+            self.ax1.autoscale_view()  # Rescale axes
+
+        colors = [
+            '#2ecc71' if c >= MIN_SAMPLES
+            else '#f39c12' if c > 0
+            else '#e74c3c'
+            for c in counts
+        ]
+        
+        # Update each bar's height and color
+        for bar, count, color in zip(self.bars, counts, colors):
+            bar.set_height(count)
+            bar.set_facecolor(color)
+            
+        self.ax2.relim()
+        self.ax2.autoscale_view()
+
+        self.canvas.draw_idle()
+        
+    # ── Export ────────────────────────────────────────────────
+
+    def _export(self):
+        with self.data_lock:
+            counts = self.counts.copy()
+            means  = self.means.copy()
+        if not counts.any():
+            messagebox.showwarning('No data', 'No data collected yet.')
+            return
+
+        ts       = datetime.now().strftime('%Y%m%d_%H%M%S')
+        out_path = DATA_DIR / f'a0_calibration_{ts}.xlsx'
+        has      = counts > 0
+        pd.DataFrame({
+            'mm_val':  bucket_centers[has],
+            'avg_adc': np.round(means[has], 3),
+        }).to_excel(out_path, index=False)
+
+        short = int(np.sum((counts > 0) & (counts < MIN_SAMPLES)))
+        empty = int(np.sum(counts == 0))
+        msg   = f'Exported {int(has.sum())} rows to:\n{out_path}'
+        if short:
+            msg += f'\n\n{short} bucket(s) have data but < {MIN_SAMPLES} samples.'
+        if empty:
+            msg += f'\n{empty} empty bucket(s) omitted.'
+        messagebox.showinfo('Exported', msg)
+
+    # ── Cleanup ───────────────────────────────────────────────
+
+    def on_close(self):
+        self._stop()
+        try:
+            if self.ser and self.ser.is_open:
+                self.ser.write(b'X')
+                self.ser.close()
+        except Exception:
+            pass
+        self.root.destroy()
+
+
+if __name__ == '__main__':
+    root = tk.Tk()
+    app  = CalibrationApp(root)
+    root.protocol('WM_DELETE_WINDOW', app.on_close)
+    root.mainloop()

AltSensorTesting/AltSensorTesting.ino

@@ -1,123 +1,125 @@
 #include <Arduino.h>
 #include <util/atomic.h>
 
-// ── ADC Interrupt-driven single-channel read (A0) ────────────
-volatile uint16_t adc_result = 0;
-volatile bool     adc_ready  = false;
+// ── ADC Interrupt-driven 3-channel read (A2, A3, A0) ─────────
+// Channel index: 0 → A2 (sensor 0), 1 → A3 (sensor 1), 2 → A0 (raw ref)
+static const uint8_t adc_mux[3] = {2, 3, 0};
+
+volatile uint16_t adc_result[3] = {0, 0, 0};
+volatile bool     adc_ready[3]  = {false, false, false};
+volatile uint8_t  adc_channel   = 0;
 
 void setupADC() {
-  // Reference = AVCC (5 V)
-  ADMUX = (1 << REFS0);
-
-  // Channel = A0 (MUX[3:0] = 0000)
-  ADMUX &= 0xF0;
-
-  // Prescaler = 16  → 16 MHz / 16 = 1 MHz ADC clock
-  // Each conversion ≈ 13 ADC clocks → ~76.9 kHz sample rate
-  ADCSRA = (1 << ADEN)  | (1 << ADIE)
-         | (1 << ADPS2);               // ADPS = 100 → /16
-
-  // Start first conversion
+  ADMUX = (1 << REFS0) | adc_mux[0];  // AVCC ref, start on A2
+  ADCSRA = (1 << ADEN) | (1 << ADIE) | (1 << ADPS2);  // /16 prescaler
   ADCSRA |= (1 << ADSC);
 }
 
-// ── OOR digital input ────────────────────────────────────────
-#define OOR_PIN 2          // digital pin 2 — HIGH = out of range
+// ── OOR digital inputs ───────────────────────────────────────
+#define OOR_PIN_0  12    // HIGH = out of range, sensor 0 (A2)
+#define OOR_PIN_1  13    // HIGH = out of range, sensor 1 (A3)
 
-volatile bool OOR;
+volatile bool OOR[2];
 
 ISR(ADC_vect) {
   uint16_t sample = ADC;
-  // Discard if OOR pin (PD2) is HIGH
-  OOR = (digitalRead(OOR_PIN));
-  if (!OOR) {
-    adc_result = sample;
-    adc_ready  = true;
+  uint8_t ch   = adc_channel;
+  uint8_t next = (ch + 1) % 3;
+
+  if (ch < 2) {
+    // Sensor channels: filter by OOR
+    OOR[ch] = digitalRead(ch == 0 ? OOR_PIN_0 : OOR_PIN_1);
+    if (!OOR[ch]) {
+      adc_result[ch] = sample;
+      adc_ready[ch]  = true;
+    }
+  } else {
+    // A0: no OOR, always store
+    adc_result[2] = sample;
+    adc_ready[2]  = true;
   }
-  ADCSRA |= (1 << ADSC); // kick off next conversion immediately
+
+  ADMUX = (ADMUX & 0xF0) | adc_mux[next];
+  adc_channel = next;
+  ADCSRA |= (1 << ADSC);
 }
 
-// ── ADC → mm linear mapping ─────────────────────────────────
-// ADC 185 → 16 mm,  ADC 900 → 26 mm
-// #define adcToMM(adc) (16.0f + (float)((adc) - 185) * (10.0f / 715.0f))
-#define adcToMM(adc) (0.0f + (float)((adc) - 0) * (10.0f / 1024.0f))
+// ── ADC → mm linear mappings (raw range: 16–26 mm) ──────────
+#define adcToMM0(adc) ((float)map(adc, 178, 895, 1600, 2600) / 100.0f)
+#define adcToMM1(adc) ((float)map(adc, 176, 885, 1600, 2600) / 100.0f)
 
-// ── Boundary tracking (in-range only) ────────────────────────
+// Subtract mounting offsets so both sensors share the same position frame:
+//   Sensor 0 raw 16–26 mm − 16 → 0–10 mm
+//   Sensor 1 raw 16–26 mm −  6 → 10–20 mm
+#define OFFSET_MM0  15.6f
+#define OFFSET_MM1   6.2f
+
+// ── Boundary tracking (in-range only, per sensor) ────────────
 #define TRACK_N 10
-uint16_t lowestVals[TRACK_N];
-uint16_t highestVals[TRACK_N];
-uint8_t  lowestCount  = 0;
-uint8_t  highestCount = 0;
+uint16_t lowestVals[2][TRACK_N];
+uint16_t highestVals[2][TRACK_N];
+uint8_t  lowestCount[2]  = {0, 0};
+uint8_t  highestCount[2] = {0, 0};
 
-// Insert val into a sorted-ascending array of up to TRACK_N entries
-// keeping only the N smallest values seen so far.
-static void trackLowest(uint16_t val) {
-  if (lowestCount < TRACK_N) {
-    // Array not full — insert in sorted position
-    uint8_t i = lowestCount;
-    while (i > 0 && lowestVals[i - 1] > val) {
-      lowestVals[i] = lowestVals[i - 1];
-      i--;
-    }
-    lowestVals[i] = val;
-    lowestCount++;
-  } else if (val < lowestVals[TRACK_N - 1]) {
-    // Replace the current largest of the "lowest" set
+static void trackLowest(uint8_t s, uint16_t val) {
+  uint16_t *lv = lowestVals[s];
+  uint8_t  &lc = lowestCount[s];
+  if (lc < TRACK_N) {
+    uint8_t i = lc;
+    while (i > 0 && lv[i - 1] > val) { lv[i] = lv[i - 1]; i--; }
+    lv[i] = val;
+    lc++;
+  } else if (val < lv[TRACK_N - 1]) {
     uint8_t i = TRACK_N - 1;
-    while (i > 0 && lowestVals[i - 1] > val) {
-      lowestVals[i] = lowestVals[i - 1];
-      i--;
-    }
-    lowestVals[i] = val;
+    while (i > 0 && lv[i - 1] > val) { lv[i] = lv[i - 1]; i--; }
+    lv[i] = val;
   }
 }
 
-// Insert val into a sorted-descending array of up to TRACK_N entries
-// keeping only the N largest values seen so far.
-static void trackHighest(uint16_t val) {
-  if (highestCount < TRACK_N) {
-    uint8_t i = highestCount;
-    while (i > 0 && highestVals[i - 1] < val) {
-      highestVals[i] = highestVals[i - 1];
-      i--;
-    }
-    highestVals[i] = val;
-    highestCount++;
-  } else if (val > highestVals[TRACK_N - 1]) {
+static void trackHighest(uint8_t s, uint16_t val) {
+  uint16_t *hv = highestVals[s];
+  uint8_t  &hc = highestCount[s];
+  if (hc < TRACK_N) {
+    uint8_t i = hc;
+    while (i > 0 && hv[i - 1] < val) { hv[i] = hv[i - 1]; i--; }
+    hv[i] = val;
+    hc++;
+  } else if (val > hv[TRACK_N - 1]) {
     uint8_t i = TRACK_N - 1;
-    while (i > 0 && highestVals[i - 1] < val) {
-      highestVals[i] = highestVals[i - 1];
-      i--;
-    }
-    highestVals[i] = val;
+    while (i > 0 && hv[i - 1] < val) { hv[i] = hv[i - 1]; i--; }
+    hv[i] = val;
   }
 }
 
 static void resetTracking() {
-  lowestCount  = 0;
-  highestCount = 0;
+  lowestCount[0] = highestCount[0] = 0;
+  lowestCount[1] = highestCount[1] = 0;
 }
 
 static void printBoundaries() {
-  Serial.println(F("--- 10 Lowest In-Range ADC Values ---"));
-  for (uint8_t i = 0; i < lowestCount; i++) {
-    Serial.println(lowestVals[i]);
-  }
-  Serial.println(F("--- 10 Highest In-Range ADC Values ---"));
-  for (uint8_t i = 0; i < highestCount; i++) {
-    Serial.println(highestVals[i]);
+  for (uint8_t s = 0; s < 2; s++) {
+    Serial.print(F("--- Sensor "));
+    Serial.print(s);
+    Serial.println(F(": 10 Lowest In-Range ADC Values ---"));
+    for (uint8_t i = 0; i < lowestCount[s]; i++) Serial.println(lowestVals[s][i]);
+    Serial.print(F("--- Sensor "));
+    Serial.print(s);
+    Serial.println(F(": 10 Highest In-Range ADC Values ---"));
+    for (uint8_t i = 0; i < highestCount[s]; i++) Serial.println(highestVals[s][i]);
   }
 }
 
 // ── State ────────────────────────────────────────────────────
 bool sampling = false;
+bool rawMode  = false;
 
 // ═════════════════════════════════════════════════════════════
 void setup() {
-  Serial.begin(2000000);
-  pinMode(OOR_PIN, INPUT);
+  Serial.begin(115200);
+  pinMode(OOR_PIN_0, INPUT);
+  pinMode(OOR_PIN_1, INPUT);
   setupADC();
-  Serial.println(F("Send '1' to start sampling, '0' to stop and print bounds."));
+  Serial.println(F("Send '1' to start sampling, '0' to stop and print bounds, '2' for raw ADC output."));
 }
 
 void loop() {
@@ -128,10 +130,16 @@ void loop() {
 
     if (cmd.charAt(0) == '1') {
       sampling = true;
+      rawMode  = false;
       resetTracking();
       Serial.println(F("Sampling started."));
+    } else if (cmd.charAt(0) == '2') {
+      sampling = true;
+      rawMode  = true;
+      Serial.println(F("Raw ADC output started."));
     } else if (cmd.charAt(0) == '0') {
       sampling = false;
+      rawMode  = false;
       Serial.println(F("Sampling stopped."));
       printBoundaries();
     }
@@ -140,27 +148,49 @@ void loop() {
   // ── Main sample path ────────────────────────────────────
   if (!sampling) return;
 
-  // Grab the latest ADC value atomically
-  uint16_t val;
-  bool ready;
-  bool newOOR;
+  uint16_t val[3];
+  bool ready[3];
   ATOMIC_BLOCK(ATOMIC_RESTORESTATE) {
-    ready = adc_ready;
-    val   = adc_result;
-    adc_ready = false;
-    newOOR = OOR;
+    for (uint8_t i = 0; i < 3; i++) {
+      ready[i]     = adc_ready[i];
+      val[i]       = adc_result[i];
+      adc_ready[i] = false;
+    }
   }
 
-  if (!ready) return;  // nothing new — come back next iteration
+  if (!ready[0] && !ready[1]) return;
 
-  // All values here are in-range (OOR filtered in ISR)
-  trackLowest(val);
-  trackHighest(val);
+  if (rawMode) {
+    if (ready[0]) {
+      Serial.print(adcToMM0(val[0]) - OFFSET_MM0);
+      Serial.print(F(", "));
+      Serial.println(val[2]);
+    }
+    if (ready[1]) {
+      Serial.print(adcToMM1(val[1]) - OFFSET_MM1);
+      Serial.print(F(", "));
+      Serial.println(val[2]);
+    }
+    return;
+  }
 
-  float mm = adcToMM(val);
-  Serial.print(val);
-  Serial.print(", ");
-  Serial.print(mm, 2);
-  Serial.print(" mm, ");
-  Serial.println(newOOR ? "out of range" : "in range");
+  // Apply offset for whichever sensor(s) are in range
+  if (ready[0]) {
+    float mm = adcToMM0(val[0]) - OFFSET_MM0;
+    trackLowest(0, val[0]);
+    trackHighest(0, val[0]);
+    Serial.print(val[0]);
+    Serial.print(F(", "));
+    Serial.print(mm, 2);
+    Serial.println(F(" mm (s0)"));
+  }
+  if (ready[1]) {
+    float mm = adcToMM1(val[1]) - OFFSET_MM1;
+    trackLowest(1, val[1]);
+    trackHighest(1, val[1]);
+    Serial.print(val[1]);
+    Serial.print(F(", "));
+    Serial.print(mm, 2);
+    Serial.println(F(" mm (s1)"));
+  }
 }

requirements.txt

@@ -1,67 +0,0 @@
-alembic==1.18.4
-appnope==0.1.4
-asttokens==3.0.1
-cloudpickle==3.1.2
-colorlog==6.10.1
-comm==0.2.3
-contourpy==1.3.3
-cycler==0.12.1
-debugpy==1.8.20
-decorator==5.2.1
-executing==2.2.1
-Farama-Notifications==0.0.4
-filelock==3.25.2
-fonttools==4.61.1
-fsspec==2026.2.0
-gymnasium==1.2.3
-ImageIO==2.37.2
-imageio-ffmpeg==0.6.0
-ipykernel==7.2.0
-ipython==9.10.0
-ipython_pygments_lexers==1.1.1
-jedi==0.19.2
-Jinja2==3.1.6
-joblib==1.5.3
-jupyter_client==8.8.0
-jupyter_core==5.9.1
-kiwisolver==1.4.9
-Mako==1.3.10
-MarkupSafe==3.0.3
-matplotlib==3.10.8
-matplotlib-inline==0.2.1
-mpmath==1.3.0
-nest-asyncio==1.6.0
-networkx==3.6.1
-numpy==2.4.2
-optuna==4.7.0
-packaging==26.0
-pandas==3.0.1
-parso==0.8.6
-pexpect==4.9.0
-pillow==12.1.1
-platformdirs==4.9.2
-prompt_toolkit==3.0.52
-psutil==7.2.2
-ptyprocess==0.7.0
-pure_eval==0.2.3
-pybullet==3.2.7
-Pygments==2.19.2
-pyparsing==3.3.2
-python-dateutil==2.9.0.post0
-PyYAML==6.0.3
-pyzmq==27.1.0
-scikit-learn==1.8.0
-scipy==1.17.0
-seaborn==0.13.2
-setuptools==82.0.1
-six==1.17.0
-SQLAlchemy==2.0.46
-stack-data==0.6.3
-sympy==1.14.0
-threadpoolctl==3.6.0
-torch==2.10.0
-tornado==6.5.4
-tqdm==4.67.3
-traitlets==5.14.3
-typing_extensions==4.15.0
-wcwidth==0.6.0